HIAB K-HiPro 505 X4 Operator's Manual
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HIAB K-HiPro 505 X4 Operator's Manual

HIAB K-HiPro 505 X4 Operator's Manual

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HIAB K-HiPro 505
X4
Operator's Manual GB
This operator's manual is an Original Instruction and applies to cranes with serial numbers from:
5050001.
2021-07

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Summary of Contents for HIAB K-HiPro 505 X4

  • Page 1 HIAB K-HiPro 505 Operator's Manual GB This operator’s manual is an Original Instruction and applies to cranes with serial numbers from: 5050001. 2021-07...
  • 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

    2.5. Accessories on the boom system ........... 12 2.6. Operating system - hydraulic components ......... 14 2.7. LHV Load holding valves ............. 15 2.8. Description of HIAB K-HiPro 505 ............ 15 3. Safety precautions and warnings .............. 16 3.1. Operating conditions ..............16 3.2.
  • Page 4 8.4. Lubrication ................100 8.4.1. Lubrication schedule ............102 8.4.2. Greasing the upper column bearing and three-point bridge ... 103 8.4.3. Lubrication of slide pads in boom system ....... 103 8.4.4. Lubrication of the hooks ........... 104 HIAB K-HiPro 505 X4...
  • Page 5 9.1. Decommissioning a crane ............119 10. Technical Data ................. 121 10.1. Load plate table ..............121 10.2. Identification of the loader crane ..........122 10.3. Abbreviations ................ 122 10.4. Daily inspection checklist ............123 10.5. Monthly inspection checklist ............124 HIAB K-HiPro 505 X4...
  • Page 6 This page is intentionally left blank. HIAB K-HiPro 505 X4...

  • Page 7: Introduction

    • Store the Technical Data and manuals from the Installer, together with this Operator's manual. NOTE The manufacturer reserves the right to change specifications, equipment, operating instructions and maintenance instructions without prior notice. HIAB K-HiPro 505 X4...

  • Page 8: Cleanliness Certificate

    Equipment (the “Information”). Such Information may be used for optimizing the Equipment, or any related equipment or services as well as for Hiab's internal business and/or operating purposes. Hiab shall be responsible for complying with applicable laws and regulations related to such Information.
  • Page 9 Never operate the crane when you are sick, tired, under the influence of medicines, alcohol, or other drugs. • Take the delivery instructions from your Hiab authorised service workshop, or receive instruction from an experienced person from your own company before you start to operate your crane.
  • Page 10 • Carry out yourself only the service and maintenance work you have the requisite knowledge and experience of. • All other maintenance work may only be carried out by a Hiab authorised service workshop. • Make sure that every defect is rectified immediately, according to the instructions.

  • Page 11: Structure And Parts Of The Crane

    Structure and parts of the crane 2. Structure and parts of the crane 2.1. 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 12: Boom System

    Add-on lifting accessories are placed between the boom tip and the load (e.g. brick grapple, rotator) or on the crane (e.g. hoist). Hooks [option] Different hooks can be mounted depending on the crane model. DANGER Never exceed the maximum permissible loading of the hook. HIAB K-HiPro 505 X4...
  • Page 13 Structure and parts of the crane Separate lifting accessories [option] Separate lifting accessories, help to make or use a slinging device: shackles, eye-bolts etc. HIAB K-HiPro 505 X4...

  • Page 14: Operating System - Hydraulic Components

    (6) Hydraulic hoses and lines (12) Load holding valve (3) Oil cooler [option] (7) Slewing cylinders / Slewing motors Pressure filter [option] (4) Main control valve Actuators: (8) First boom cylinder (9) Second boom cylinder (10) Extension cylinder/s HIAB K-HiPro 505 X4...

  • Page 15: Lhv Load Holding Valves

    To operate a hydraulic cylinder equipped with a load holding valve, an opening pressure is required. 2.8. Description of HIAB K-HiPro 505 The HIAB K-HiPro 505 are compact, fully hydraulically operated goods cranes. Stress history class S2 according to EN 13001-1. Lifting capacity: •...

  • Page 16: Safety Precautions And Warnings

    In cold weather, start the crane as follows: • Engage the power take-off at low rpm. • Allow the system to idle for a few minutes. • Operate stabiliser legs up and down for one minute, in order to warm up the oil. HIAB K-HiPro 505 X4...

  • Page 17: Wind Speeds

    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 18 • Installation of informative posts, road signs, notice boards, traffic lights, street lights… Forbidden duties: • Crane mounted onboard ships or floating structures, only permitted in cases authorised by Hiab • Continuous use as a production crane in assembly lines, foundries…, except for cranes prepared for that purpose •...

  • Page 19: Noise Declaration

    Your crane has a certain lifting capacity, expressed in kNm, tm or fts-lbs. This lifting capacity is also known as the load moment. The lifting capacity is: the payload at hook multiplied by the outreach in HIAB K-HiPro 505 X4...
  • Page 20 • The reach at which you are working and the optimum position of the boom. • The optimal position for your crane is on the load plate. DANGER Never exceed the maximum weight on the load plate. HIAB K-HiPro 505 X4...

  • Page 21: 2Nd Boom Dual Capacity

    3.3.4. 2nd Boom dual capacity Depending on the boom system angles, the capacity of the crane is optimized to get the best performance in each position. HIAB K-HiPro 505 X4...

  • Page 22: Maximum Load Moment

    • 1st boom down (certain crane types and cases) Lifting the load Make sure that you always have the work in clear view. If you cannot see the load properly, you could cause a fatal accident or serious damage. HIAB K-HiPro 505 X4...
  • Page 23 Lift heavy loads with the 2nd boom in the optimum position in relation to the 1st boom. For this, see the load plate on your crane. DANGER Never exceed the maximum permissible loading of the hook. HIAB K-HiPro 505 X4...

  • Page 24: Signals When Using A Crane [Ar+]

    Signals in this manual give a number of standard signals that can be used. Lift Raised arm and index finger raised. Circular motion with the hand. Lower Arm pointing downwards and index finger down. Circular motion with the hand. HIAB K-HiPro 505 X4...
  • Page 25 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 both hands. Thumbs inwards. HIAB K-HiPro 505 X4...
  • Page 26 Extend the arms at shoulder height, with the palms facing downwards. Close the tool Move both hands close together. Lift the open tool a little Extend both arms at shoulder height, with the palms facing upwards. Make vertical movements with both arms outstretched. HIAB K-HiPro 505 X4...

  • Page 27: Use Of The Crane

    • The stabiliser legs must not sink in! Use support plates that are large and firm enough for your crane. The plates must not bend because of the load weight. • Verify that the support plates do not sink as you gradually lift the load. HIAB K-HiPro 505 X4...
  • Page 28 (grapple, rotator). Separate lifting accessories are connected to the standard load hook (slings, chains, shackles etc). DANGER Do not stand in front of the boom system when operating the crane out of transport position. HIAB K-HiPro 505 X4...

  • Page 29: Preparations For Use

    DANGER • If a part of the crane comes in contact with an electricity line, you will be electrocuted! • Always keep following minimum distances between crane overhead electricity lines, unless otherwise prescribed by national rules. HIAB K-HiPro 505 X4...

  • Page 30: Crane Operation

    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 operating instructions! HIAB K-HiPro 505 X4...
  • Page 31 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 ends positions at full speed. This can damage the crane. HIAB K-HiPro 505 X4...
  • Page 32 Your crane has a rack-and-pinion slewing system which provides more than 360° of rotation. As part of the initial orientation and training: Look at the plate(s) on the column to see the position of the 'slewing stop' (slewing stops). HIAB K-HiPro 505 X4...
  • Page 33 (B). CAUTION Repeated rotation of the crane against the slewing stops during operation can cause major crane base damage. If this operation happens, it will be considered as a misuse of the crane. HIAB K-HiPro 505 X4...
  • Page 34 To avoid possible collision between the boom tip and rotator/hoses: Elevate the 1st boom as necessary (nearly full elevation in close range positions). Use the 2nd boom extensions to reach the position needed. HIAB K-HiPro 505 X4...

  • Page 35: Driving With The Crane

    Make sure that no part of the crane ever comes in contact with overhead power lines. NOTE • For further instructions, refer to the vehicle's manual(s). • Make sure that you always obey local traffic rules when driving with a crane. HIAB K-HiPro 505 X4...

  • Page 36: Use Of Lifting Equipment

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

  • Page 37: Use Of Demountable Cranes

    • Disengage the PTO or power supply after work. • If you drive with the PTO or power supply engaged, this will cause serious damage to the PTO/gearbox combination. • Only after doing the above, you can drive the vehicle away. HIAB K-HiPro 505 X4...

  • Page 38: 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 authorised service workshop. 4.2. How the safety system works On the crane there are various sensors and indicators which send signals about the crane’s load,...

  • Page 39: Components Of The Hipro System

    (1) Main control valve (4) Dump valve 1 (7) Warning lamp (2) Stabiliser control valve (5) Dump valve 2 [option] (8) XSDrive controller [option] (3) User panel SPACE X4-UI (6) Pressure-reducer filter (9) CombiDrive controller [option] HIAB K-HiPro 505 X4...

  • Page 40: Standard Symbols And Functions Of The Crane And The Stabiliser System

    Always operate the lever according to the function on the symbol sign. Basic crane symbols and functions SYMBOLS FUNCTIONS SYMBOLS FUNCTIONS Slewing Second boom Hydraulic First boom extensions Accesories symbols and functions. (If delivered). SYMBOLS FUNCTIONS SYMBOLS FUNCTIONS Rotation tool Tool Tool HIAB K-HiPro 505 X4...

  • Page 41: Main Control Valve

    When remote control is used, the oil flow is allocated by means of PFD. Standard functions and symbols The order of the functions is customized for each crane. The image on the right shows an example of a main control valve functions placed on the base. HIAB K-HiPro 505 X4...

  • Page 42: Different Stabiliser Control Valves

    • Stop button (4) is pushed in an emergency. • Button (5) is used to sound the crane horn. • Button (6) activates OLP for manual extensions (if fitted). • Button (7) activates the controller. 4.7.1. Indicator LEDs on User Interface HIAB K-HiPro 505 X4...
  • Page 43 Red light blinking: Critical error. Dump valve Blue light on: Dump activated. Blue light on: Indicates that the ADC feature is active. Hoist (10) Not active in this configuration. (11) Not active in this configuration. (12) VSL-OLP reached. HIAB K-HiPro 505 X4...

  • Page 44: Dump Valves

    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 User Interface before the stabiliser system can be controlled. HIAB K-HiPro 505 X4...

  • Page 45: Pressure-Reducer Filter

    12 outputs for servo valves. The status of the receiver is visible on the controller. In case of radio interference, it is possible to change the channel by pushing button . There is a maximum of 12 channels available. HIAB K-HiPro 505 X4...
  • Page 46 The cable (2) is intended to be used for short-term operation and when pairing in conjunction with the replacement of controller or receiver. Connection is made between the controller (3) and the receiver box (1). Radio communication is automatically disabled when the cable is connected. HIAB K-HiPro 505 X4...

  • Page 47: Indicator Leds On Xsdrive Controller

    Lower LEDs, red light flashing: 90% of maximum pressure Lower and upper LEDs red light: 100% of maximum pressure Manual Not active in this configuration. extension Green light on: Increased capacity (ADC mode) Menu LEDs (10) Light on: Indicates active menu HIAB K-HiPro 505 X4...

  • Page 48: Buttons

    (8) deactivates it. Channel shift Push to change radio channel. There are 12 channels in total. Emergency stop When you push the button, you stop all crane button functions. To release it, turn the button clockwise. HIAB K-HiPro 505 X4...

  • Page 49: Menus

    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: Menu 1 Slewing, first boom, second boom, extension boom, tools JIB, hoist, etc.

  • Page 50: Standard Functions And Symbols

    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 HIAB K-HiPro 505 X4...

  • Page 51: Battery And Battery Charger Xsdrive

    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. HIAB K-HiPro 505 X4...

  • Page 52: Displays

    +10 °C whenever not in use. Centre display The center display provides information about which menu has been chosen, as well as indicating for example radio reception, battery status, fault information, ADC and VSL. Indications on the centre display SR VC HIAB K-HiPro 505 X4...
  • Page 53 Indicates that the ADC function is When the symbol begins to flash active. there is capacity for just a few more minutes. When this happens the horn on the crane will sound twice as an indication of low battery. HIAB K-HiPro 505 X4...

  • Page 54: Buttons

    Menu CRANE Stop button Push to choose menu CRANE. Push to deactivate the controller. Release to activate. Menu EXTRA OLP release Push to choose menu EXTRA. Push and hold to activate OLP release. See section “OLP release”. HIAB K-HiPro 505 X4...

  • Page 55: Menus, Standard Functions And Symbols

    The function of each lever may be the same or different in different menus. The left and right displays show which function is controlled by each lever. The function symbols show a direction (up, down, left, right) which applies to when the lever is moved forwards. HIAB K-HiPro 505 X4...
  • Page 56 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 HIAB K-HiPro 505 X4...
  • Page 57 Example of submenus for the 6 lever controller: Left side display Centre Right side display display "CRANE MENU" Example of submenus for the 8 lever controller: Centre Left side display Right side display display "CRANE MENU" HIAB K-HiPro 505 X4...
  • Page 58 The ON-OFF menu includes functions such as engine start, stop and throttle. The functions are shown as text instead of symbols in the displays. A lever may be moved in any direction in order to activate the corresponding function. ON-OFF 1 HIAB K-HiPro 505 X4...

  • Page 59: Battery And Battery Charger

    (1) and (2) lights during charging. (1) and (3) lights when the battery is fully charged. Display B Shows the battery voltage (8.4). When the display blinks 0.0 there is error in the battery: Change battery. HIAB K-HiPro 505 X4...
  • Page 60 A charged battery is a concentrated energy source. Never store a charged battery in a toolbox or similar, where there is a risk of a short due to metal components. Used batteries should be taken care of according to the local regulations. HIAB K-HiPro 505 X4...

  • Page 61: Starting Crane Operation

    NOTE • Operating the crane in to and out of transport position must also be done with the vehicle completely levelled. • Activate the parking brake and place chocks under the wheels to prevent vehicle movement. HIAB K-HiPro 505 X4...
  • Page 62 To start the control system, push the On/Off button on the User Interface. The LED above the button lights up. The system will check itself for a few seconds. The warning lamps on the stabiliser legs light up. HIAB K-HiPro 505 X4...
  • Page 63 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. On the decoder LED (2) on gives a steady light and LED (1) flickers. HIAB K-HiPro 505 X4...

  • Page 64: Set The Stabiliser System

    The stability sector indication will change according to the stabiliser system position. • Cranes without VSL: the stability sector LEDs will light green regardless of the situation. The operator is the responsible to make sure that the vehicle is stable while lifting a load. HIAB K-HiPro 505 X4...

  • Page 65: Stabiliser System And Ground Conditions

    265-285 395-425-505-335K-410K-435K 322-377-328-352-362-388 Medium stab. exten. 422-477 Long stab. exten. Extra long stab. exten. 358-398-408-418 528-548-558-638-658 858-1058 HIAB Auxiliary stabilisers NOTE Sign that shows the maximum force that the stabiliser legs can apply to the ground. HIAB K-HiPro 505 X4...

  • Page 66: Activate The Stabiliser System

    The procedure of setting the stabiliser extensions differs depending on the type of stabiliser extensions. Repeat the instructions for the stabiliser extension on the other side of the vehicle. For auxiliary stabiliser system [option]: Repeat the process. HIAB K-HiPro 505 X4...

  • Page 67: Set The Stabiliser Legs [Ar+]

    Repeat the instructions for the stabiliser extension and leg on the other side of the vehicle. For auxiliary stabiliser system [option]: Repeat the process. WARNING Take care not to lower the stabiliser leg onto your foot. HIAB K-HiPro 505 X4...
  • Page 68 Operate the stabiliser leg downwards until it is set to the ground. Hydraulically controlled tiltable stabiliser legs [AR+] DANGER Do not stand in the tilting area. Make sure the tilting mechanism remains unlocked during the complete tilting. HIAB K-HiPro 505 X4...

  • Page 69: Operate The Boom System Out Of Transport Position

    DANGER Always operate a manually controlled crane from the position shown in the image! 1. If the stabiliser system is manually controlled, push button on the User Interface to activate remote control. HIAB K-HiPro 505 X4...
  • Page 70 Extend the 1st boom hydraulic extensions. Extend the 2nd boom 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. HIAB K-HiPro 505 X4...

  • Page 71: During Operation

    6.1.2. Controlling the crane speed with the controller CombiDrive At startup the crane speed is set to 100%. It is possible to choose between three different speeds. Push button (7) to change. Current speed is shown as a percentage on the display. HIAB K-HiPro 505 X4...

  • Page 72: Supervision Of Spools

    The next lever movement stops the dumping and it functions as normal. 6.1.6. ASC Automatic Speed Control The ASC feature 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. HIAB K-HiPro 505 X4...

  • Page 73: Adc Automatic Duty Control

    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. HIAB K-HiPro 505 X4...

  • Page 74: Vsl Variable Stability Logic [Option]

    Examples of stability diagrams: Stability diagram (One on/off sensor on stabiliser extensions) With one On-Off sensor, you see two curves and two positions of the stabiliser extensions: Not fully extended 0-99% (shown as 0%) Fully extended (100%) HIAB K-HiPro 505 X4...
  • Page 75 For cranes with JIB, you will have an additional diagram. The Lifting Capacity Diagram: The software creates six different capacity diagrams with the stabiliser extensions in different positions (represented in the truck drawing). For cranes with JIB, another six capacity diagrams will be automatically generated. HIAB K-HiPro 505 X4...

  • Page 76: Vsl+ (Variable Stability Logic Plus) [Option]

    (degrees) and also by the outreach of the boom extensions (meters or feet and inches). NOTE Speak to your Hiab authorised service workshop to request these diagrams for other loads. 6.1.11. VSL+ (Variable Stability Logic Plus) [option] VSL+ is a patented feature that automatically optimises the crane's capacity in relation to the vehicles stability.
  • Page 77 In order to get the maximum benefit from the VSL+ system, some of the wheels of the vehicle shall be lifted from the ground but Hiab strongly recommends that at least one wheel is braked by the parking brake and has contact with the ground.

  • Page 78: Lss-V Load Stabilising System-Vertical [Option]

    OLP is a safety function that prevents overloading of the crane. With 90% of maximum permitted pressure the warning lamps on the stabiliser legs double blink. When 100% of maximum pressure is reached the warning lamps will blink. HIAB K-HiPro 505 X4...
  • Page 79 Move the levers to neutral and only operate permitted (pressure reducing) functions. OLP manual control If one prohibited function is used, all functions will stop. The crane will be fully operational as long as only allowed functions are used. HIAB K-HiPro 505 X4...

  • Page 80: Olp - Indications On The Controller

    Operate permitted (pressure reducing) functions only. In an OLP situation, symbol "x" is shown in every menu in the centre display. 100% HIAB K-HiPro 505 X4...

  • Page 81: To Release Olp

    The wait will increase in three steps: 30, 60 and maximum 90 seconds. During each 5 second interval only one function at a time can be operated. Extension out cannot be operated at all. The 5 second interval starts to count down as you move the lever. HIAB K-HiPro 505 X4...
  • Page 82 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 Interface the cylinder pressure LEDs perform a running light. The LED for padlock symbol will blink red. HIAB K-HiPro 505 X4...

  • Page 83: Ending Crane Operation

    Slew the crane until the crane is parallel to the vehicle. Retract the 2nd boom hydraulic extensions completely. Retract the 1st boom hydraulic extensions completely. Lower the boom system against the vehicle. (Do not extend the second boom cylinder fully). HIAB K-HiPro 505 X4...

  • Page 84: Placing The Stabiliser System In The Transport Position [Ar+]

    User Interface to deactivate the controller. Activate stabiliser system operation on the User Interface by pressing button ◦ Remote controlled stabiliser system: Select on the controller the defined menu for the stabiliser system operation. HIAB K-HiPro 505 X4...
  • Page 85 Turn the lever (2) -180º and check that the locking pin (1) is in and the lever (2) cannot rotate. Retract the stabiliser leg completely. Retract the stabiliser extension completely. HIAB K-HiPro 505 X4...
  • Page 86 • Make sure that you can see them clearly during their operation. • Be prepared to reduce the speed of the operation to prevent accidents. • Make sure that the stabiliser legs are fully up and locked. HIAB K-HiPro 505 X4...

  • Page 87: Switching Off The Control System

    If you are using the remote controller: • Push the stop button on the controller and switch off the control system. • Disengage the PTO. 7.4. Emergency operation Valve-V200 EMERGENCY operation to bring the crane to transport position Do like this: HIAB K-HiPro 505 X4...
  • Page 88 DANGER To operate the crane like this is HIGHLY DANGEROUS because during emergency operation all crane security is disconnected. Always go to/contact a Hiab authorised service workshop when the seal wire has been broken. Engage the pump. Break the security sealing on dump valve 1 (1) on the main control valve.

  • Page 89: Transport Warning [Option]

    To operate the crane like this is HIGHLY DANGEROUS because during emergency operation all crane security is disconnected. Always go to/contact a Hiab authorised service workshop when the seal wire has been broken. Follow actions 1-5 in previous section "EMERGENCY operation to bring the crane to transport position".
  • Page 90 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 the lifting accessories to prevent any unintentional movement of the crane and the lifting accessories. HIAB K-HiPro 505 X4...

  • Page 91: Maintenance And Service

    DANGER • Do not do any welding work on the crane. Welding work on the crane may only be carried out by a Hiab authorised service workshop, or in close consultation with Hiab. • Do not drill into the crane yourself. Drilling...

  • Page 92: Warranty

    • The "Warranty – Terms and Conditions" specified in the "Service & Warranty Manual" are fulfilled. • The crane is inspected and maintained, by a Hiab authorised service workshop as specified in the "Service & Warranty Manual". • Original HIAB parts are used for every repair or maintenance work.
  • Page 93 Maintenance intervals: • Carried out by the operator: daily and monthly inspection. • Carried out by Hiab or a Hiab authorised service workshop: ◦ 1st service: to be made after 50 hours of use. ◦ Regular service: to be made when one of these conditions are met: ▪...
  • Page 94 NOTE Always lubricate after cleaning the crane. WARNING Keep the devices to go into the control station (handles, supports, platforms...) clean from oil, grease and dirt to prevent slipping and falling. HIAB K-HiPro 505 X4...

  • Page 95: Daily Inspection

    • Check that the Stop buttons are undamaged and working properly. Levers • Check that the levers operate smoothly. • Check that the levers return to neutral position. Controller • Do a check of the controller functionality. HIAB K-HiPro 505 X4...
  • Page 96 In the event of damage that presents a safety risk: • Do not use the crane. • Have the damage repaired immediately by a Hiab authorised service workshop. Hooks Always keep the hook clean. Use a cloth to wipe away any dirt.
  • Page 97 In the event of damage or worn to prevent a safety risk: • Do not use the hook. • Have the damage repaired immediately by a Hiab authorised service workshop. Add-on equipment and separate accessories (hoist, JIB, etc.) • Check the cables, cable connections, the cable guides and the attachment points for the add-on equipment.
  • Page 98 • Make sure that all security seal wires (Ex. LHV, dump valves, etc...) are not broken. Always go to/contact a Hiab authorised service workshop when the seal wire has been broken. • Check oil level in the tank. If necessary, fill to correct level.

  • Page 99: Monthly Inspection And Maintenance

    • Inspect all the pivot pins and bushings for the crane boom and cylinders for damage, play, etc. Bolts and screw fixings • Check that bolt and screw fixings are tight. If not, contact a Hiab authorised service workshop Cables and sensors •...

  • Page 100: Annual Maintenance

    Maintenance and Service 8.3.3. Annual maintenance Take the crane, at least once a year, to a Hiab authorised service workshop for inspection and maintenance. The workshop must carry out the following maintenance tasks at least once a year. Hydraulic oil •...
  • Page 101 Do NOT grease with graphite or molybdenum-disulphide additives. Recommended greases: BP LS EP 2, ESSO UNIWAY EP2 N, AGIP GR MU/EP3, NYNÄS UNIFETT EP. Alternative: Use a Teflon grease spray to lubricate the extensions and mobile parts. HIAB K-HiPro 505 X4...

  • Page 102: Lubrication Schedule

    Maintenance and Service 8.4.1. Lubrication schedule Lubricate after every 16 hours of use. Lubricate after every 50 hours of use. Grease after every 50 hours of use. A: Internal pads, B: Internal guides HIAB K-HiPro 505 X4...

  • Page 103: Greasing The Upper Column Bearing And Three-Point Bridge

    • Extend extensions with load in order to create enough clearance. • Lubricate. Front lower slide pads • Extend extensions without load and push slightly against the ground in order to create enough clearance. • Lubricate. HIAB K-HiPro 505 X4...

  • Page 104: Lubrication Of The Hooks

    Oil level checking Measuring stick or level glass • Check if the oil level on the measuring stick (1) or on the level glass (2) is between the maximum and minimum levels. HIAB K-HiPro 505 X4...

  • Page 105: Checking Of The Oil Level Of The Tank

    Clean the area around the oil filler cap. Fill with oil up to the max level indicator. CAUTION • Never fill the tank completely, because during operation, the volume of the oil could expand as the temperature increases. • Never use recycled oil! HIAB K-HiPro 505 X4...
  • Page 106 Hydraulic oils must have been dealt with according 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 107: Replacement Of Filters

    Hiab strongly recommends an oil working temperature below 70°C. If necessary consider an oil cooler or heater. NOTE If you need to work at a temperature below -25, contact a Hiab authorised service workshop. Environmentally friendly oil The environmentally friendly oils recommended for HIAB products are ester based synthetic hydraulic fluids (synthetic ester).

  • Page 108: Bleeding Air From The Hydraulic System

    Slowly raise and lower the 1st and the 2nd boom to its end position at least twice. If the crane is equipped with JIB, slowly raise and lower the JIB at least twice with main boom system pointing downwards and upwards. HIAB K-HiPro 505 X4...

  • Page 109: Troubleshooting

    MUX box. Truck warning interface, Work lights. Fuse for all Hydraulic main control valve, 10 A Located inside the components stabiliser leg warning lamp, User standard box (2). connected to the Interface, MUX box. Truck standard box. warning interface. HIAB K-HiPro 505 X4...

  • Page 110: Faults On The Crane

    Faults in the crane must be rectified immediately. DANGER • Only correct yourself the faults that according to the table you may rectify. • Follow the instructions exactly! • All other faults must be corrected by personnel in a Hiab authorised service workshop! Fault Probable cause...
  • Page 111 Oil level in the tank is bleed the hydraulic immediately! too low. system. Hydraulic pump is Go to a Hiab authorised faulty. service workshop. 1. Push in the Stop button [If fitted]. Leak on hydraulic system: leaking 2. Disengage the PTO.
  • Page 112 Maintenance and Service Fault Probable cause Action The bearings in the Go to a Hiab authorised slewing housing are service workshop. damaged. Insufficient oil in the Top up the oil tank. hydraulic system. Insufficient oil in the Top up the oil in the gear gear box.

  • Page 113: Display [Option]

    Maintenance and Service Fault Probable cause Action Cylinder internal Go to a Hiab authorised leakage. service workshop. Boom extensions shake during extending/retracting function. Sequence screw in Tight the screw in the cylinder head loose. right position. Extension load Go to a Hiab authorised...
  • Page 114 The green indicates the highest percentage of the maximum pressure indicates lowestpercentage. NOTE The percentages refer to the maximum pressure available in each sector in the 1st boom cylinder, not the percentage of the maximum net load shown the load plate. HIAB K-HiPro 505 X4...

  • Page 115: Error Codes

    You can see the codes if you have the external display or a display on your controller. If you have an error that is not in the following list, you must speak to your Hiab authorised service workshop.

  • Page 116: Gateway Connection Box [Option]

    2. Put electric grease on both the connector and the JIB plug. 3. Set the system to OFF and then back to ON. If you can still see the error, go to a Hiab authorised service workshop. E186: SAF This error appears only when you move a lever for SAF.
  • Page 117 • Poor GPS signal strength. 5 blinks The gateway is not • Software is updating. operational yet. NOTE If the system stops while the software is updating, the update will be put on hold until the system starts again. HIAB K-HiPro 505 X4...
  • Page 118 Error 2 and 3 exist in the system. NOTE If error 1, 2, and 3 exist in the same time, do a check that you have the correct Gateway kit (EU for European Union or US for United States, Canada and Mexico). HIAB K-HiPro 505 X4...

  • Page 119: Decommissioning

    Energy waste can be utilised by incinerating it at a proper waste incineration plant. • Spiral wraps, manufactured from polyethene, plastic, bearings (cleaned of lubricants) used in the column, beam system etc, manufactured from polyamide plastic. HIAB K-HiPro 505 X4...
  • Page 120 EU legislation. When one of these parts reaches the end of its life, take it to a collection site designated by local authorities. Responsible collection and recycling help protect natural resources, the environment, and human health. HIAB K-HiPro 505 X4...

  • Page 121: Technical Data

    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. m/ft kg/lbs HIAB K-HiPro 505 X4...

  • Page 122: Identification Of The Loader Crane

    • SSL - ('Sector Stability Limit') - Sector Stability Limit • UI - ('User Interface') - User Interface • VSL - ('Variable Stability Logic') - Variable Stability Logic • VSL+ - ('Variable Stability Logic Plus') - Variable Stability Logic Plus HIAB K-HiPro 505 X4...

  • Page 123: Daily Inspection Checklist

    Horn and LED test If you find a fault that prevents you from operating the crane safely, contact a Hiab authorised service workshop. Do not try to repair the fault, it can cause you injury or you can damage the equipment.

  • Page 124: Monthly Inspection Checklist

    Pump attachment screws Gateway connectivity If you find a fault that prevents you from operating the crane safely, contact a Hiab authorised service workshop. Do not try to repair the fault, it can cause you injury or you can damage the equipment.

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