HIAB 322 HiPro CD Operator'S Manual Download Page 41

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The Safety system

Operator's Manual GB

4.2

• When prohibited movements/speeds are ap-

proached, a warning is given.

• When prohibited movements/speeds are

reached:

On remote controlled cranes prohibited move-
ments are stopped.

On manually operated cranes, all movements
are stopped, because when a spool is moved
too much, power to the dump valve is cut, all
movements are stopped.

Fault monitoring

When there is a fault in the safety system it will
give an immediate warning.

Depending upon the fault the crane speed and/or
the load capacity will be reduced. When the fault
is serious, use of the crane is blocked completely.

DANGER

Never try to repair the safety system yourself.
Repairs may only be made by a HIAB service
workshop!

Summary of Contents for 322 HiPro CD

Page 1: ...This operator s manual is an Original Instruction and applies for cranes from serial number 3221631 3771320 2015 06 Operator s Manual GB HIAB 322 377 HiPro CD ...

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

Page 3: ...that can be fitted in a 322 377 HiPro 16 3 Safety precautions and warnings 17 3 1 Operating conditions 17 3 2 Definition of a HIAB loader crane 18 3 2 1 Noise declaration 19 3 2 2 Warning signs 20 3 2 3 Maximum load 20 3 2 4 Maximum load moment 23 3 3 Signals when using a crane 26 3 4 Wind speeds 30 3 5 Use of the crane 31 3 6 Use of lifting equipment 38 3 7 Use of dismountable cranes 38 4 The Saf...

Page 4: ...on 77 6 1 OLP Overload protection 77 6 2 BDA Boom Deployment Assistance option 80 6 3 Manual extensions option 80 7 Ending crane operation 83 7 1 Operate the crane to parking position 83 7 2 Placing the stabiliser extensions and legs in transport position 84 7 3 Switching off the safety system 87 7 4 Emergency operation Valve V91 88 7 5 TWI Transport warning interface option 89 8 Maintenance and S...

Page 5: ...ge in return oil filter 101 8 5 3 Replacing the cartridge in the pressure reduction filter 102 8 5 4 Checking the oil tank level 102 8 5 5 Changing the hydraulic oil 102 8 5 6 Bleeding air from the hydraulic system 105 8 6 Troubleshooting 106 8 6 1 Main fuses 106 8 6 2 Faults in the HiPro crane 106 9 Decommissioning 110 9 1 Decommissioning a crane 110 10 Technical Data 112 10 1 Documentation 112 ...

Page 6: ... not study the complete Operator s Manual for your crane carefully it could lead to fatal accidents or serious damage Therefore you should Study the entire Operator s Manual carefully Study the operating manuals for other add on equipment if fitted Use the crane only after having done so Follow the directions for use operation and maintenance of the crane and add on equip ment exactly Store the Te...

Page 7: ...o the Equipment the Information The Customer shall not in any way remove or alter the System nor interfere with the use of the System or the Information The System and the Information and all their further developments shall at all times be and remain the exclusive property of HIAB without granting any right or license to the customer 1 2 Indications in the Operator s Manual What must you do and n...

Page 8: ... reference to a component in an illustration Refers to a component in an illustration option Indication for parts that are not standard for the crane but are an option DANGER Only persons with the requisite knowledge and experience with cranes may use the crane Never operate the crane when you are sick tired under the influence of medicines alcohol or other drugs Take the delivery instructions fro...

Page 9: ...med by personnel in a HIAB service workshop 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 safety system Never immerse the controller in water or other liquid This will make the controller unusable If your crane is equipped with...

Page 10: ...and slewing system Boom system Stabiliser system Operating system 2 2 Crane base with column and slewing system The crane base column and the slewing sys tem consist of the following components Crane base with stabiliser beam column bearings and three point bridge Column this fitted to the crane base and turns in an upper and a lower bearing Slewing system ...

Page 11: ...oom 2nd boom Hydraulic extensions The length of the hydraulic extension depends on the type of crane Manual extensions option These are slid by hand into the hydraulic extension JIB option Add on lifting accessories option Add on lifting accessories are placed between the boom tip and the load e g brick grapple rotator or on the crane hoist ...

Page 12: ...12 Structure and parts of the HIAB crane Operator s Manual GB 2 3 Separate lifting accessories option Separate lifting accessories help to make or use a slinging device eye hooks shackles eye bolts etc ...

Page 13: ...may be needed for heavy cranes Stabiliser beam The stabiliser beam is a part of the crane base Stabiliser extensions The stabiliser exten sions are hydraulically slid out from the stabiliser beam Stabiliser legs Place the stabiliser legs on firm levelled ground to support the crane Stabiliser locking device Support plates The support plates are used under the stabiliser legs for additional sup por...

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

Page 15: ...pplied in many versions from HIAB 322 377E 4 reach 11 7 metres to HIAB 322 377E 8 reach 21 0 metres HIAB 322 377EP 2 reach 8 0 metres to the HIAB 322 377EP 5 reach 15 1 metres The main control valve V91 CombiDrive2 and the SPACE 5000 safety system are standard equipment on the HIAB 322 377 HiPro CD The crane type and the manufacturer are marked on the serial number plate NOTE The exact technical i...

Page 16: ... 377 E 5 6 JIB70X 3 4 TC1 322 377 E 4 5 JIB100X 4 5 TC1 TC2 322 377 EP 2 3 4 5 TC2 322 377 E 4 5 TC2 TC2L Not compatible with manu al extensions in 322 377 E 5 6 377 E 8 JIB 70X 3 322 377 E 6 7 8 TC2L 322 377 E 5 6 JIB70X 3 4 TC2L 322 E 5 6 JIB75X 4 TC2L Only available in MEWP version 322 377 E 4 5 JIB100X 4 5 TC2L Snatch block for TC2 and TC2L Available in all combinations except in the configura...

Page 17: ... ex ceeds 13 3 m sec approx 29 7 mph the crane will behave unpredictably Never use the crane during a thunderstorm Never use the crane at temperatures below 40 C 40 F as the steel s properties deteriorate below this temperature WARNING At temperatures below 0 C 32 F Do not touch the operating levers during the first few minutes When starting in cold weather the wear on the hydraulic system is grea...

Page 18: ...e Lifting of loads from the ground vehicle to a higher place Installation work beams concrete plates windows in building constructions Lifting construction material wall boards bricks blocks on a pallet fork to a build ing taking the material from the vehicle on which the crane is mounted from another vehicle or from the ground Hoisting e g beams concrete plates and any other material and equipmen...

Page 19: ...inst the ground unless the crane is specifically prepared for this Push pull with the boom system against any type of obstacle wall ground Using the JIB upside down HiPro cranes except JIBs prepared for that See Operator s Manual for your JIB 3 2 1 Noise declaration The following values for emitted noise may be taken as general and conservative values for ordinary installations of loader cranes on...

Page 20: ...r s Manual GB 3 2 2 A weighted sound pressure level at loader crane control stations in accordance with ISO 11201 LpA 95 dB Uncertainty KpA 4 dB Particular installations can be quieter in which case a post installation noise measurement in accordance with clause 6 3 of EN 12999 2011 may be used to prove this 3 2 2 Warning signs 3 2 3 Maximum load Lifting capacity ...

Page 21: ...ad plate and the load diagram on your crane show the maximum loads you may lift in the operating reach of your crane DANGER Overloading could result in damage to the crane or in the worst case personal injury or death Never increase a hanging load since that may cause a load holding valve to open and or the vehicle to turn over Never use the crane with the OLP system switched off NOTE The extra we...

Page 22: ...for your crane is on the load plate DANGER Never exceed the maximum weight on the load plate Load diagram The load diagrams are placed on the column and show the maximum loads your crane 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 The white area is the working zone of the cra...

Page 23: ...to push or compress loads when the first boom is fully lifted as this could cause damage to the first boom cylinder 3 2 4 Maximum load moment If your crane has reached the maximum load moment lifting capacity the OLP gives a warning and locks any crane movement that will increase the load moment This is known as an OLP situation If the second boom is raised then the following movements are locked ...

Page 24: ...le 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 WLL of a single leg by a mode factor in accordance with the table Max angle to the vertical of any sling leg degrees Mode factor two legged sling Mode factor three and four...

Page 25: ...nd keep the first boom angle to about 10 to 30 above the horizontal plane Heavy loads Lift heavy loads with the second boom in the optimum position in relation to the first boom For this see the load plate on your crane DANGER Never exceed the maximum permissible load ing of the hook Heavy loads cannot be handled with the boom straight Set the second boom so there is an angle in relation to the fi...

Page 26: ...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 The country specific regulations for crane operator signals are to be used Signals in this manual give a number of standard signals that can be used Lift Raised arm and index finger raised Circular motion with hand Lower Arm...

Page 27: ...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 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 Sidewa...

Page 28: ...ings Operator s Manual GB 3 3 Turn in the direction indicated Indicate the direction with the hands Open the grapple Extend the arms at shoulder height with the palms facing downwards Close the grapple Move both hands close together ...

Page 29: ...al GB 3 3 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 30: ... begin to move over the ground 5 8 0 10 7 Fairly strong wind Small leaved branches make swaying movements crested waves form on lakes and canals 6 10 8 13 8 Strong wind Large branches move you can hear the wind whistling in telephone wires umbrellas can only be held with diffi culty 7 13 9 17 1 Severe wind Entire trees move the wind causes difficulty when you walk into it 8 17 2 20 7 Stormy wind T...

Page 31: ...he ground is not undermined Look out for sewers cellars excavations etc The stabiliser legs must not be able to sink in Use support plates that are large and firm enough for your crane The plates must not bend under load Check that the support plate as it comes under load is not pushed into the ground Ensure you can see the stabiliser legs and stabiliser extensions when you are operat ing them Do ...

Page 32: ... legs while the crane has a load WARNING Use low force when placing the stabiliser legs on the ground Do not raise the vehicle with the stabiliser legs if the crane is equiped with only two stabiliser legs If you raise the vehicle with the stabiliser legs this may damage the stabiliser legs Check that the add on lifting accessories and separate lifting accessories are in good order Add on lifting ...

Page 33: ...and in front of the boom system when operating the crane out of parking position Preparations for use DANGER Ensure that there are no unauthorised persons within the operating range of your crane TIP Mark out the working range e g with cones Put on your vehicle s warning lights ...

Page 34: ...ed conductor Minimum dis tance to an un insulated con ductor 500 V 0 5 m 2 m 500 40000 V 1 5 m 4 m 40000 V 2 0 m 6 m Voltages are found up to 500 V to buildings 500 40000 V trams trains over 40000V power transmisson Crane operation DANGER Your crane has a safety system The safety system will help you to work safely Nevertheless you remain responsible for safe use of the crane Therefore always work...

Page 35: ...u signals See the list of signals Make certain that you and the person assisting you know these signals Pay attention to the safety of the person giving the signals Never move the vehicle if you have a freely suspended load on the crane Never walk or stand under a suspended load During operation never stand below the boom system or load Do not slew the crane nor lift the first boom nor lift the se...

Page 36: ...orking with loads in restricted spaces for example windows Check that the boom system can move up and down freely The boom system will bend somewhat when loading and unloading the crane If the boom system is in a high position first boom above 70 do not allow the boom to lower at full speed The crane could go into an uncontrolled movement Be careful if in particular the OLP gives an early warning ...

Page 37: ...can not hit bridges tunnels etc Pay attention to overhead power lines Make sure that no part of the crane ever comes in contact with overhead power lines For further instructions see vehicle s manual s Ending crane operation DANGER Always end crane operation as follows After use always place the crane in the transport position Withdraw the stabiliser legs and stabiliser extensions Check that the l...

Page 38: ... hazards Never try to adjust lifting accessories when you are working on the crane After the lifting accessories have been fitted 1 Check that the lifting accessories are securely fixed 2 Only after this should you use your crane WARNING Clean the couplings when connecting and disconnecting lifting accessories Dirt can damage the hydraulic system Take care that your fingers are not trapped 3 7 Use...

Page 39: ...39 Safety precautions and warnings Operator s Manual GB 3 7 WARNING Take care when mounting dismounting the crane on off the vehicle Roughly handling can seriously damage the crane or the vehicle ...

Page 40: ...ion Control Valve Safety system HiPro CD V91 SPACE 5000 NOTE The safety system provides a large number of functions Certain functions are standard others are options If you do not use the system for 30 minutes it will switch itself off in order to prevent draining the truck battery This feature can be cancelled Contact your HIAB service workshop 4 2 How the safety system works The safety system wo...

Page 41: ...ents are stopped because when a spool is moved too much power to the dump valve is cut all movements are stopped Fault monitoring When there is a fault in the safety system it will give an immediate warning Depending upon the fault the crane speed and or the load capacity will be reduced When the fault is serious use of the crane is blocked completely DANGER Never try to repair the safety system y...

Page 42: ...positioners with filtered oil Dump valve 1 To prevent high pressure and thereby unnec essary heating of the oil there is an automatic dumping function When no lever movement has been made for 3 seconds SPACE system opens the dump valve and the oil is returned directly to the hydraulic tank As soon as the operator moves a lever the valve closes Dump valve 2 Allows operation of the stabiliser extens...

Page 43: ...rol valve V91 stabiliser control valve user panel SPACE 5000 remote control CombiDrive2 with radio with cable connected 4 5 Main control valve The speed of a function corresponds to the extent of the lever movement regardless of the load and other functions as long as the oil flow is sufficient When the oil flow is insufficient one or more functions might reduce their speed When remote control is ...

Page 44: ...44 The Safety system Operator s Manual GB 4 5 Main control valve lever function Remote control lever function ...

Page 45: ... control valve option The stabiliser control valve is equipped with 4 levers The levers have the functions Extra stabiliser extension out in Extra stabiliser leg upward downward stabiliser extension out in stabiliser leg upward downward The 4 levers of one side operate the stabiliser extensions and legs of that side The stop button affects the oil supply to this valve The stabiliser control valve ...

Page 46: ...where the crane operator stands while manually operating the crane 4 10 User panel SPACE 5000 Cranes with remote control type CombiDrive2 and control valve type V91 are equipped with user panel SPACE 5000 Functions Stop button When you push the stop button all crane movements are stopped immediately ON OFF button with the symbol to switch the safety system On Off Button with the symbol To switch o...

Page 47: ...is stopping the crane Diagnostic required Red double flash CAN error crane stops OLP Release Red light on OLP Red light blinking OLP release button has been pressed 5 sec to release OLP Slewing sector Light off Inside slewing sector reduced capacity Red light on OLP Vehicle has reached a stability limit Also all the 1st boom diodes will light red Green light on Dump valve 1 activated Automatic dut...

Page 48: ... release Remote control Green light on Remote control Good radio connec tion Green light blinking Stop button pressed no radio connection Red light blinking Radio interference Manual extensions Green light on Manual extension selected Green light blinking Manual extension selected and 1st manual extension out but 1st crane extension not out Manual control Green light on Manual control Stabiliser s...

Page 49: ...on The centre display provides information about which menu has been chosen as well as indicat ing the radio reception conditions battery status fault information micro ADC manual extension and so on The side displays show the symbol for the function which each lever activates in the chosen menu When the operator changes menu the symbols change to the functions that become active Via cable A four ...

Page 50: ...ols are completely changed Alternating symbols will not be updated at tem peratures below freezing In order to prevent accidental menu shifts in cold weather below 10 C there will be a time delay before any menu button will react to a second depression In order to avoid this inconvenience HIAB recommends that whenever the controller is not in use it should be stored in a compart ment where the tem...

Page 51: ...rged for three seconds and then return to normal size LSS Load Stabilizing System op tion Indicates that the LSS V function is active MEWP Mobile Elevating Work Plat form Indicates that MEWP if present is active HDC Indicates that the HDC function is active Signal strength The bars show the radio signal strength Five bars indicate optimum reception condi tions If the symbol flashes the radio is co...

Page 52: ...stem Non critical error Symbol appears enlarged in the center of the display After three seconds it returns to normal size and moves to the upper part of the display Critical error Symbol remains enlarged in the center of the display The crane stops Error code display The control system has the possibility to send error codes to the controller By pressing button on the left hand side below the dis...

Page 53: ...n with three pushbuttons Button CRANE menu Button EXTRA menu button ON OFF menu In each of the main menus the operator can step through submenus by pressing the same button repeatedly e g 1 2 3 and then back to 1 again The restriction is that one function is only present on a specific lever If a lever is faulty or deflected at startup the lever is disabled The other levers operate in the usual way...

Page 54: ...rvice personnel For every lever there is a correspond ing function which it controls This appears in the left or right display When the menu changes by pressing the button for CRANE menu the symbols change and the functions are activated in the current menu The symbols are stored in a symbol library and can be configured set via the terminal program for a CE crane Symbols for the 8 lever controlle...

Page 55: ...1 2 3 55 The Safety system Operator s Manual GB 4 12 Symbols for the 6 lever controller CRANE MENU Left side display Centre display Right side display ...

Page 56: ...ally positioned in relation to the lever The symbols are configured in the same way as for the CRANE menu The same method is used for stepping between the sub menus Left is defined as the side of the crane where the main control valve is normally placed The order of the levers is customized For the 6 lever controller If the crane has 1 stabiliser control valve the order of the levers should be Lev...

Page 57: ...ft auxiliary stabiliser leg down Menu 3 Lever Functions lever forward on the con troller 2 Right crane stabiliser extension out 3 Right crane stabiliser leg down 4 Right auxiliary stabiliser extension out 5 Right auxiliary stabiliser leg down For the 8 lever controller If the crane has 1 stabiliser control valve the order of the levers should be Lever Functions lever forward on the con troller 3 L...

Page 58: ...ons lever forward on the con troller 1 Left auxiliary stabiliser extension down 2 Left auxiliary stabiliser leg out 3 Left crane stabiliser extension down 4 Left crane stabiliser leg out 5 Right crane stabiliser extension out 6 Right crane stabiliser leg down 7 Right auxiliary stabiliser extension out 8 Right auxiliary stabiliser leg down ...

Page 59: ...ions Instead text can be entered directly into the window that corresponds to each function Only ordinary numerals and the letters of the English alphabet can be used For each sub menu four functions may be defined The functions are controlled by levers 2 5 A lever may be deflected in any direction in order to activate the corresponding function ON OFF MENU Left side display Centre display Right s...

Page 60: ...charging time for a flat battery is approximately 3 hours The battery charger is designed not to damage the battery even during long continuous charging Operating ambient temp Battery 0 to 45 C A charged battery The voltage level of a fully charged battery is approximately 8 4V and it provides about 5 8 hours working time Note that the battery voltage remains between 7 6V and 7 5V for a long time ...

Page 61: ...ions Locking unlocking the controller The controller can be locked to prevent unauthor ised persons from starting the controller and operating the crane Locking the controller 1 Press and hold button and while the stop button is pressed 2 Keep button and pressed while pulling out the stop button The centre display then shows a large locked padlock symbol Unlocking the controller 1 Press and hold b...

Page 62: ...receives a signal and shuts OFF the system For emergency operation During 5 seconds it is possible to activate the SPACE system by pressing the ON OFF button on the user interface 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 norma...

Page 63: ...Control The purpose of the ADC function is to increase the lifting capacity by 10 The first boom pressure sensors indicate if there is a positive or negative pressure on the first boom Normal capacity If the first boom is pressed down the sensors indicate a negative pressure and the lifting capacity is normal during the complete lifting cycle Increased capacity ADC mode ADC lamps light up If the s...

Page 64: ...the lever to 50 or 20 of normal speed Slewing sector option Within slewing sector lifting capacity can be reduced due to stability The overload warning will be given at a lower load in the limited sector than outside the sector In case of an overload warning you may slew out of the sector but not further into it ...

Page 65: ...horizontal position When the bubble is between the two circles the crane inclination is between 0 and 5 If the slope exceeds the permitted inclination unintentional crane movements can occur Particular case Working with boom sys tem beyond 60 To avoid side deflection and in order to guarantee the safest operation when working with e g hoist and or JIB MEWP applica tions the vehicle has to be compl...

Page 66: ...em might overheat Rpm too low during crane operation the vehicle s engine could stall The maximum rpm may depend upon a governor on your PTO combination CD2 Start the safety system The operating levers must be in neutral position before start up To activate the system press the On Off button on the user panel The LED above the button starts to blink The system will check itself 2 4 seconds ...

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

Page 68: ...roller will always start in CRANE 1 menu regardless of which menu was active when the controller was stopped CD2 Operating the stabiliser system WARNING All levers must be in neutral position DANGER When you are operating the stabiliser exten sions Make sure that you have full view of the stabiliser extensions Do not stand in front of hydraulically operated stabiliser extensions From remote contro...

Page 69: ...en sions and legs from the stabiliser leg valve 5 2 Extend stabiliser extensions and set stabiliser legs To ensure the full stability all the stabiliser extensions and legs must be fully extended and set to the ground without lifting the wheels off the ground WARNING Take care not to lower the stabiliser leg to your foot DANGER Check that the support plates do not bend or sink into the ground WARN...

Page 70: ...he maxi mum ground pressure is less than 4MPa Operation with non tiltable stabiliser legs 1 Unlock the catcher 2 Extend the stabiliser extension 3 Set the stabiliser leg to the ground Repeat for the stabiliser extension and leg on the other side of the vehicle When there is an additional set of stabiliser legs option Repeat the process for the 3rd and 4th stabiliser legs ...

Page 71: ...ansport position DANGER Do not stand in the stabiliser leg tilting area 3 Tilt the stabiliser leg downward 4 Lock the stabiliser leg lock 5 Extend the stabiliser extension 6 Set the stabiliser leg to the ground Repeat for the stabiliser extension and leg on the other side of the vehicle When there is an additional set of stabiliser legs option Repeat the process for the 3rd and 4th stabiliser legs...

Page 72: ...n lock the catcher and the handle 2 Place your right hand on the handle while unlocking the stabiliser leg with your left hand Make sure the leg drops in a controlled movement until it stops 3 Push the handle until the leg points down 4 Lock the stabiliser leg Repeat for the stabiliser extension and leg on the other side of the vehicle When there is an additional set of stabiliser legs option Repe...

Page 73: ...ted free of the vehicle 3 Tilting the stabiliser leg WARNING To minimise the risk for the stabiliser leg to tilt down by itself retract the stabiliser leg Unlock the stabiliser leg lock DANGER Do not stand in the tilting area Make sure the tilting mechanism remains unlocked during the complete tilting Operate the lever to extend the stabiliser leg This will also tilt the leg to vertical position ...

Page 74: ...he ground WARNING Always check that the stabiliser legs and the stabiliser extensions are in correct position and tilting mechanism is locked in working position Repeat for the stabiliser extension and leg on the other side of the vehicle When there is an additional set of stabiliser legs option Repeat the process for the 3rd and 4th stabiliser legs ...

Page 75: ...is reason study the operating instruc tions for add on equipment carefully Once the stabiliser extensions and legs are ready you can start using the crane 1 If stabiliser system is under manual control push button on the user panel 2 If using remote control push button on the controller to change the menu into crane operation DANGER Always operate manually controlled crane from the position indica...

Page 76: ...tical position as shown in the figure to be able to free the extension from the catcher 4 Extend the first extension until it comes free of the catcher 5 Raise the boom system 6 Slew the crane to the working position 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 ...

Page 77: ...d a pre warning is given The yellow lamp on the lamp pole option flashes and the cylinder pressure LED s flash red When 100 of the maximum permitted pressure is reached the OLP cuts in The display shows whether a particular motion is prohibited or if the crane is subject to OLP The red and the amber lamps on the lamp pole option will light all the time and the cylinder pressure LED s will light co...

Page 78: ...ure sensor reaches 100 all motions that would increase torque are blocked If the operator attempts to activate a blocked function the function symbol is replaced by a cross while the lever is deflected When the lever is returned to the neutral position the cross disappears and the information returns Operate permitted load reducing functions only NOTE Do not operate heavy loads with the extensions...

Page 79: ...move the lever During this period it is possible to operate an appropriate crane function so as to correct the overload situation Only one unallowed function at a time can be operated Extension out cannot be operated The unlocked padlock will appear in the centre display On the user panel the cylinder pressure LEDs and the LED for padlock symbol will flash red Manual control If one prohibited move...

Page 80: ...utton to allow second boom and extensions movements DANGER Only use the BDA override to get the crane out of a locked position Operating the crane out of parked position When the angle ß is 135º between the horizontal and second boom second boom and extensions can move without any restrictions 6 3 Manual extensions option Operation with manual extensions Always extend the hydraulic extensions firs...

Page 81: ...n for the maximum load that can be handled Do not lift loads heavier than the values stated on the hook attachment To lift heavier loads than specified on the sign 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 t...

Page 82: ...ush and hold both Release button and Horn button until symbol on the centre display is lit The lamp for manual extension is lit on the user panel The manual extensions are now included in the OLP protection The lifting capacity will be reduced automatically De activate Push the button and again The symbol on the centre display goes out The lamp for manual extension goes out on the user panel ...

Page 83: ...oints 4 5 1 Slew the crane until the crane is square on the vehicle 2 Retract all extensions 3 Raise the first boom 4 Operate the second boom to vertical position as shown in the figure To be able to lock the extensions slide out the first extension about 500 mm NOTE Take care not to damage the catcher during this operation Retract the first extension slowly and adjust the second boom to ensure th...

Page 84: ...sition and securely locked WARNING Do not put your foot on the support plate Operation with non tiltable stabiliser legs 1 Retract the stabiliser leg 2 Retract the stabiliser extension completely WARNING Risk of crushing injuries Always keep hands away from moving parts during operation 3 The catcher will lock the stabiliser exten sion Repeat for the stabiliser extension and leg on the other side ...

Page 85: ...ly 4 Lock the stabiliser leg lock 5 Retract the stabiliser extension completely WARNING Risk of crushing injuries Always keep hands away from moving parts during operation 6 The catcher will lock the stabiliser exten sion Repeat for the stabiliser extension and leg on the other side of the vehicle When there is an additional set of stabiliser legs option Repeat the process for the 3rd and 4th stab...

Page 86: ...ent 4 Push the leg up until it reaches parking position 5 Lock the stabiliser leg 6 Retract the stabiliser extension completely For manually operated stabiliser extension unlock the handle Retract the extension and lock it again Check that the catcher is secured WARNING Risk of crushing injuries Always keep hands away from moving parts during operation Repeat for the stabiliser extension and leg o...

Page 87: ...the stabiliser leg remains unlocked during the complete tilting 3 Lock the stabiliser leg lock 4 Retract the stabiliser extension completely WARNING Risk of crushing injuries Always keep hands away from moving parts during operation 5 The catcher will lock the stabiliser exten sion Repeat for the stabiliser extension and leg on the other side of the vehicle When there is an additional set of stabi...

Page 88: ...tion to bring the crane to parking position Do like this On the main control valve 1 Break the security sealing on dump valve 1 on the inlet section 2 Press the dump valve button and turn 90 degrees until it is blocked 3 Operate the crane to parking position using the levers on the main control valve ...

Page 89: ...ing the levers on the stabiliser control valve DANGER To operate the crane like this is HIGHLY DANGEROUS because during emergency op eration all crane security is disconnected Always go to contact a HIAB service work shop when the seal wire has been broken 7 5 TWI Transport warning inter face option WARNING If you switch off the safety system when manual operated stabiliser extensions tiltable sta...

Page 90: ...an be silenced by an acknowledgement button option or by a signal indicating that the parking brake of the vehicle is engaged The vehicle must not be moved 1 Switch the system on put the crane into the transport position 2 Switch off the system The vehicle may be moved DANGER After use always put the crane into the transport position When you have to park the boom on the load space or over the loa...

Page 91: ...t 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 Never try to reinstall the crane Only a HIAB Dealer may reinstall the crane Before carrying out any welding on the vehi cle Disconnect the power between the vehicle and the crane Contact the vehicle manufacturer After welding on the vehicle Connect the power ...

Page 92: ...n the power supply has been switched off Always contact a HIAB service workshop Deal with an oil leak as follows 1 Rest the crane on the floor or on the truck platform 2 Switch off the operating system 3 Disengage the PTO 4 Leaking coupling Tighten the coupling with a spanner If tightening does not help contact a HIAB service workshop 5 Small leak on a line or hose Determine if you can still park ...

Page 93: ...op Carry out yourself only the service and maintenance work you have the requisite knowledge and experience of If the crane is not be used for 1 month or longer Lubricate the crane thoroughly according to the lubrication schedule Park the crane in the transport position Filters Replace the filter cartridge after the first 50 hours operation then after every 500 hours operation or at least twice a ...

Page 94: ...ock and hook suspension Check that these are in good condition Levers Check that the levers operate smoothly Check that the levers return to the neutral position Electronic components Check that these are in good condition Crane structure Check for damage to the crane structure e g any formation of cracks DANGER In the event of damage that presents a safety risk Do not use the crane Have the damag...

Page 95: ...nts for the add on equipment Maintain all add on equipment auxiliary equipment etc according to the instructions supplied with it Oil tank level To check the level in the oil tank Place the vehicle on level ground with the crane in transport position If necessary top up Slewing housing oil level Check the oil level in the slewing housing If necessary top up 8 3 2 Monthly inspection and mainte nanc...

Page 96: ...rs for damage play etc Bolts and screw fixings Check that bolt and screw fixings are tight ened Cables and sensors on the boom system Check that these are in good condition Lubrication schedule Carry out the lubrication according to the instructions Hydraulic system Check that the hydraulic pump attachment screws are tightened Check if the oil in the hydraulic system needs to be changed Add on equ...

Page 97: ...being used in hot climates the oil might need to be changed more often Slewing housing Change oil in the slewing housing 8 4 Lubrication WARNING Follow the lubrication schedule exactly If you not do so there may be serious damage to the crane and to add on equipment Type of grease Use lithium based grease containing EP additives consistencies 2 and 3 are recommended depend ing on the climate Recom...

Page 98: ...98 Maintenance and Service Operator s Manual GB 8 4 1 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 ...

Page 99: ...he 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 Lubricate Lower slide pads Extend extensions without load and push slightly against the ground in order to create enough clearance Lubricate ...

Page 100: ...cating the upper column bear ing without help Lubricate the upper bearing with a little grease Slew the crane a little Again lubricate with a little grease Repeat until the column has been slewed round completely 8 5 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...

Page 101: ... 5 viscosity SAE 80W 90 3 Slew the crane after filling to the end positions three times 4 Check the oil level If necessary top up again 8 5 2 Replacing the cartridge in return oil filter Return oil filter with fouling indicator WARNING Dirt will damage the hydraulic system Make sure that the area around the filter is clean to prevent contamination of the hydraulic oil 1 Unscrew and remove the cove...

Page 102: ... 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 8 5 5 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 th...

Page 103: ... Ensure the waste oil is disposed of safely and inaccordance with local environmental regula tions 4 Change at the same time all filters 5 Refit the drain plug Filling the oil tank with hydraulic oil The oil used for filling must be clean Do not mix different oils Hydraulic oil that is approved for HIAB products must comply with one of the following standards or equivalents DIN 51524 part 3 SS 15 ...

Page 104: ... 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 Environmentally Friendly Oil The environmentally friendly oils recommended for HIAB products are ester based synthetic hydraulic fluids synthetic ester NOTE Vegetable oils...

Page 105: ...nging the hydraulic oil after working on the hydraulic system if your crane works slowly or jerkily WARNING Air in the hydraulic system can lead to faults and damage To bleed air from the hydraulic system pro ceed as follows Move each crane cylinder and each hydraulically operated piece of add on equipment at least twice to its end positions slowly ...

Page 106: ...e the fuses in The user panel bottom 2x15A The user panel cover 2x7 5A and 3x3A Check all cable connections and close the covers 8 6 2 Faults in the HiPro crane Faults in the crane must be rectified immediately DANGER Only correct yourself the faults that ac cording to the table you may rectify Follow the instructions exactly All other faults may be dealt with only by personnel in a HIAB service w...

Page 107: ...se Three causes Warning Stop using the crane immediately Oil tank filler cap air filter is blocked Clear the blockage or re place the entire filler cap Oil level in the tank is too low Top up the oil tank and bleed the hydraulic system The pump is faulty Go to a HIAB service work shop The stabiliser extensions do not slide out The extensions are still locked Unlock the extensions Hydraulic fault G...

Page 108: ...IAB ser vice workshop External Display option Placing The unit shall be placed under the plastic cover together with the SPACE box where it is pro tected from direct water splash Start up The External display automatically starts when the SPACE system is started Operating modes The display has three basic operating modes 1 Use time mode default 2 Error display mode 3 Config mode Use time mode defa...

Page 109: ...n start showing errors as The number of active errors and a dot Each active error in turn Blank display if no errors Start over Press the button again to return to Use time mode Example 3 active errors 003 014 and 028 Clear errors In Error display mode errors can be cleared as in SPACE terminal by pressing the button for 2 seconds until the clear errors symbol is shown in the display ...

Page 110: ...ned properly Most of the crane s raw materials can be recycled Follow the regulations of the local authorities Oil and grease must not be spilled on to the ground or released into the environment Drain the oil from hydraulic cylinders valves and hoses Sort the waste Deliver the metal parts for recycling for reuse as raw material These are load bearing struc tures manufactured from steel or cast ir...

Page 111: ...es 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 solid lubricants greases from the joints and journal bearings other waste containing oils and greases hy draulic oil filters ...

Page 112: ...ual GB 10 10 1 Documentation The Technical Data document shows diagrams and technical information about your specific crane The enclosed Technical Data printed out by the installer should be stored together with this Operator s manual ...

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