HIAB X-Duo 044 Operator'S Manual Download Page 117 | Manualshive

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117

Maintenance and Service

Operator's Manual GB

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. The different sec-
tors are marked in colors green, yellow, grey or
red where green indicates the highest percentage
of lifting capacity and red indicates the lowest
percentage.

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Summary of Contents for X-Duo 044

Page 1: ...ator s manual is an Original Instruction and applies to cranes with serial number from BL044DO00001 BL078DU00001 BL088DO00001 BL102DU00001 BL112DU00001 2018 01 Operator s Manual GB HIAB X Duo 044 078 088 102 112 ...

Page 2: ...iarize yourself with your crane before you start to use it Help us to improve this manual Please send your comments and suggestions to documentation hiab com This manual includes interactive contents Download the Hiab AR App for the interactive content in this manual Look for the AR symbol Use your device to scan the image next to the symbol The interactive contents in the Hiab AR App will display...

Page 3: ...HV Load holding valves 18 2 8 Description of HIAB X Duo 18 3 Safety precautions and warnings 19 3 1 Operating conditions 19 3 2 Wind speeds 20 3 3 Definition of a HIAB loader crane 21 3 3 1 Determination Hoist 23 3 3 2 Noise declaration 23 3 3 3 Signs on the crane 24 3 3 4 Maximum load AR 24 3 3 5 Maximum load moment 26 3 4 Signals when using a crane AR 29 3 5 Use of the crane 32 3 5 1 Preparation...

Page 4: ...abiliser system 55 5 2 3 Extend the stabiliser extensions AR 56 5 2 4 Set the stabiliser legs AR 57 5 3 Operate the boom system out of transport position 60 5 3 1 BDA Boom Deployment Assistance option AR 61 6 During operation 63 6 1 Functions 63 6 1 1 OPS Operator Protection System option 63 6 1 2 APO Automatic power off 63 6 1 3 ADO Automatic dump function 64 6 1 5 Slewing sector option 64 6 2 OL...

Page 5: ...5 Check rope 93 8 3 6 Cleaning the rope 93 8 3 7 Course and requirements of the rope 94 8 3 8 Change of rope 95 8 3 9 Maintenance and monitoring of rope end 97 8 4 Lubrication 97 8 4 1 Lubrication schedule 98 8 4 2 Lubrication of the upper column bearing 99 8 4 3 Lubrication of the column bearings 99 8 4 4 Lubrication of the hooks 100 8 5 Hydraulics 101 8 5 1 Slewing housing checking the oil level...

Page 6: ...6 3 Display option 116 9 Decommissioning 118 9 1 Decommissioning a crane 118 10 Technical Data 120 10 1 Documentation 120 10 2 Identification of the loader crane 120 10 3 Theoretical using time Hoist 120 10 4 Performance Data TC1 rope capacity 121 10 5 Abbreviations 122 10 6 Daily inspection checklist to photocopy 123 ...

Page 7: ...t 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 Techn...

Page 8: ...he 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 Cleanliness certificate All Hiab equipment has been tested and certified at the factory according to the Hiab Standard C250 52 that defines th...

Page 9: ...ers or danger of serious damage to the crane or other objects Follow the instructions carefully CAUTION Hazard for the crane or crane components Follow the instructions carefully Important If actions are numbered 1 Do this 2 Do that 3 4 5 you should carry them out in numerical order NOTE Extra information that can prevent problems TIP Tip to make the work easier to carry out ...

Page 10: ...ons from your HIAB Service workshop or receive instruc tion from an experienced person from your own company Only then should you operate your crane Ensure that you comply with the statutory requirements of the country in which you use the crane for example certificate obligatory safety helmet DANGER Carry out yourself only the service and maintenance work you have the requisite knowledge and expe...

Page 11: ...em Never immerse the controller in water or other liquid This will make the controller unusable If your crane is equipped with add on lifting equipment hoist rotator etc The operation of the crane with add on lifting equipment can differ from the oper ation as described in this manual You should therefore study the Operating Manual for the add on equipment careful ly before you use the crane Take ...

Page 12: ...omponents Some accessories can be fitted depending on your crane configuration Manual extensions option Hoist option Add on lifting accessories option Hooks option Separate lifting accessories option 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 beams and three point bridge Column fitted to...

Page 13: ...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 Stabiliser beam Stabiliser extensions Stabiliser legs Stabiliser locking devices option Extra support plates ...

Page 14: ...oom Hydraulic extensions The length of the hydraulic extension depends on the type of crane Manual extensions option Hoist option Rope guide option Only present if the crane is equipped with a minimum of 3 hydraulic extensions Top roller option The top roller must only be attached to a hydraulic extension Never to a manual exten sion Counterweight option Hook option ...

Page 15: ...al 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 Separate lifting accessories option Separate lifting accessories help to make or use a slinging device eye hooks shackles eye bolts etc ...

Page 16: ...s far below ground level Lifting and lowering is achieved by winding unwinding the rope A number of auxiliary components are needed such as inter mediate pulleys and a hook pulley As an option a snatch block can be installed to duplicate lifting capacity The Hoist consists of the following compo nents Wear plate for rope end monitoring Pressure roller Rope Load sensor Electrical wire to load senso...

Page 17: ...erating system consists of the following hydraulic components Oil tank Stabiliser control valve option Return filter Hydraulic pump Hydraulic hoses and lines Load holding valve Oil cooler option Slewing cylinders Mo tor reducers Pressure filter option Main control valve Actuators First boom cylinder Second boom cylinder Extension cylinder s ...

Page 18: ...ad holding valves will stop the booms from collapsing down even when the hydraulic system is switched off and you operate a particular crane function To operate a hydraulic cylinder equiped with a load holding valve an opening pressure is re quired 2 8 Description of HIAB X Duo The HIAB X Duo 044 X Duo 078 X Duo 088 X Duo 102 X Duo 112 are a compact fully hydraulically operated loader cranes The c...

Page 19: ... 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 20: ... 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 21: ...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 22: ...s rivers Loading cargo that is partially loaded or fastened by other means without making sure the capacity of the crane is enough for the entire load Any duty which implies Pressure against the ground unless the crane is specifically prepared for this Push pull with the boom system against any type of obstacle wall ground DANGER Lifting people with a crane is never allowed unless it is a MEWP cra...

Page 23: ...in this manual 3 3 2 Noise declaration The following values for emitted noise may be taken as general and conservative values for ordinary installations of loader cranes on normal diesel engine powered trucks Declared dual number noise emission values in accordance with ISO 4871 Emitted A weighted sound power level for basic loader cranes in accordance with ISO 3744 LwA 103 dB Uncertainty KwA 2 dB...

Page 24: ...ity ex pressed in kNm or tm This lifting capacity is also known as the load moment The lifting capacity is the payload at hook multiplied by the outreach in metres that the crane can operate at different positions The lifting capacity of your crane determines the maximum load your crane may lift within its working zone However take careful note the greater the operating radius of the crane the low...

Page 25: ...f NOTE The extra weight of the lifting accessories has to be added to the load Thus with lifting accesso ries the load you can lift is less heavy Load plate On the plate is the maximum weight that you may lift at a given reach with the 1st boom in the optimum position In chapter Technical Data in this manual you will find these values for your crane Optimum position The weight that your crane can ...

Page 26: ... lifting capacity for some cranes is limited in the high lifting area WARNING Care must be taken when handling loads in the high lifting area so the load tool does not come into contact with the boom system WARNING Never operate the hydraulic extensions against a solid objet when the first boom is completely lifted Do not try to push or compress loads when the first boom is fully lifted as this co...

Page 27: ...th Always attach the load using the shortest possible sling The angle between the legs of the sling must not exceed 120 The maximum working load usually known as the working load limit WLL in standards of a multilegged sling for general purposes is calculated by multiplying the 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...

Page 28: ...oads Lift heavy loads with the second boom in the optimum position in relation to the first boom For this see the load plate on your crane DANGER Never exceed the maximum permissible load ing of the hook Heavy loads cannot be handled with the boom straight Set the second boom so there is an angle in relation to the first boom Loads at the extreme limit of the working zone Also in this case angle d...

Page 29: ...ed person qualified The country specific regulations for crane operator signals are to be used Signals in this manual give a number of standard signals that can be used Lift Raised arm and index finger raised Circular motion with hand Lower Arm pointing downwards and index finger down Circular motion with hand Stop all crane movements Also Hold the load in position Raise the open hand with the pal...

Page 30: ...tance apart with the palms facing each other The hands may be held either horizontally or vertically The next movement may be Lift lower move the lifting gear change the reach or turn Change the reach Signal with your hands Sideways movement outwards with both hands Thumbs outwards Sideways movement inwards with both hands Thumbs inwards Turn in the direction indicated Indicate the direction with ...

Page 31: ... 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 Make vertical movements with both arms outstretched Keep the grapple in position briefly Raise the hand drooping slightly with the fist clenched ...

Page 32: ...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 33: ...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 you raise the vehicle with the stabiliser legs this may damage the stabiliser legs Check that the add on lifting accessories and separate lifting accessories are in good order Add on lifting accessories are sometimes fitted on the crane hoist JIB or placed between th...

Page 34: ...act with an electricity line you will be electro cuted Maintain the following minimum distances between the crane and overhead electricity lines unless otherwise prescribed by na tional rules Minimum distance between crane and over head electricity lines Voltage V Minimum distance to an insulated 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 ...

Page 35: ...king that there are no unauthor ised persons within the operating reach of the crane Make certain that you can always see the load If your view of the load is not adequate have someone else give you 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 f...

Page 36: ...working 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: ...tions and warnings Operator s Manual GB 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 ...

Page 38: ...t 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 3 5 5 Use of the Hoist The hoist permits load handling without any or only limited boom movement Lifting and lowering is achieved by wind ing unwinding the rope The operator should take care during hoist oper...

Page 39: ...on the first extension This to avoid incorrect winding of the rope onto the drum 3 5 6 Use of lifting equipment DANGER Only use lifting accessories hoist grapple rotator suitable for your crane Contact a 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 access...

Page 40: ... not trapped 3 5 7 Use of demountable cranes DANGER Ensure that there are no unauthorized persons in the immediate vicinity of the crane When mount demount the crane to the vehicle people can suffer fatal crushing injuries After setting up Check that the crane is properly locked WARNING Take care when mounting demounting the crane on off the vehicle Roughly handling can seriously damage the crane ...

Page 41: ...transport position Withdraw the stabiliser legs and stabiliser extensions Check that the locking mechanisms are properly locked Switch off the operating system 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 should you drive the vehicle away ...

Page 42: ...ctions 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 On the crane there are various sensors and indicators which send signals about the crane s load position and movements to a central micro processor...

Page 43: ...er to the dump valve is cut all movements are stopped Fault monitoring When there is a fault in the control 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 control system yourself Repairs may only be made by a HIAB service worksh...

Page 44: ...1 2 44 The Duo system Operator s Manual GB 4 3 4 3 Components of the Duo system Main control valve User panel Microprocessor ...

Page 45: ... 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 Always operate the lever according to the func tion on the symbol sign Basic crane symbols and functions SYMBOLS FUNCTIONS SYMBOLS FUNCTIONS Slewing Second boom First boom Hydraulic extensions ...

Page 46: ...red SYMBOLS FUNCTIONS SYMBOLS FUNCTIONS JIB cylinder Hoist Rotation tool JIB extensions Tool 2 Stabiliser system symbols and functions if delivered SYMBOLS FUNCTIONS SYMBOLS FUNCTIONS Crane stabiliser ex tension Crane stabiliser leg Auxiliary stabiliser extension Auxiliary stabiliser leg ...

Page 47: ...r of the functions is customized for each crane The image on the right shows an example of a main control valve func tions placed on the base 4 6 Different stabiliser control valves Different stabiliser control valves that you can find on cranes 2 function 4 function control valve included in the main control valve 2 function control valve 4 function control valve You can operate the stabiliser co...

Page 48: ...erating the stabiliser extensions outward OLP release button is used for OLP release in OLP situations Stop button is pressed in an emergency Horn button sounds the horn if present Manual extensions button acti vates deactivates OLP for manual extensions 4 7 1 Indicator LEDs on user panel Power on off Green light on The system is on Green light Blinking System on and the stop button has been press...

Page 49: ...ht on Error in the system Red light flashing Critical error Dump valve Blue light on Dump activated ADC Blue light on Crane has enhanced capacity ADC mode Hoist Green light on Hoist mode Red light flashing 90 of OLP pressure Red light on 100 of OLP pressure VSL Not active in this configuration Stabiliser legs Not active in this configuration Stability sector Green light on regardless of the situat...

Page 50: ... system to stop the boom system slewing into the platform DANGER Never operate the crane in or out of parking position from the platform 4 9 High seat option For manually controlled cranes The high seat is equipped for using tools and operated by two joystick levers and two foot pedals The control valve is placed at the high seat Remote controlled cranes The high seat is equipped with a holder for...

Page 51: ... s Manual GB 4 9 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 ...

Page 52: ...n horizontal position When the bubble is between the two circles the crane inclination is between 0 and 5 Working with boom system beyond 60 To avoid side deflection and in order to guarantee the safest operation when working with e g Lifting Accessories and or Hoist applications the vehicle has to be completely levelled in any direction α 0º NOTE Operating the crane in to and out of transport pos...

Page 53: ...mps on the stabiliser legs if fitted light up 5 2 Set the stabiliser system To ensure the maximum stability of the vehicle all the stabiliser extensions and legs must be fully extended and set to the ground without lifting the wheels off the ground Cranes with VSL when the stabiliser exten sions are not fully extended the lifting capac ity is optimized by the function VSL to ensure the maximum sta...

Page 54: ... to stability given that the stabiliser leg is to be set in the present position The stability sector indication will change in accordance with the stabiliser leg being operated in either direction Cranes with VSL the stability sector LEDs will indicate crane capacity in six different sectors due to stability given that the stabilis er leg is to be set in the present position The stability sector ...

Page 55: ...imum permitted ground inclination under the stabiliser leg plate is 5º The maximum load that the stabiliser leg can impose on the ground Crane Model P KN 044 046 058 062 88 2 068 072 078 082 088 092 102 108 112 118 122 149 5 DANGER Check that the extra support plates do not bend or sink into the ground Do not lower the stabiliser legs on the edge of an embankment soft ground hollows etc Lower the ...

Page 56: ...side of the vehicle For auxiliary stabiliser system option Repeat the process Manually controlled stabiliser extensions Unlock Stabiliser locking devices and Take a firm grip around handle and pull to extend the stabiliser extension and lock with the handle Hydraulically controlled stabiliser exten sions Unlock the Stabiliser locking device option and extend the stabiliser extensions with the leve...

Page 57: ...ARNING Take care not to lower the stabiliser leg onto your foot NOTE For cranes with VSL the stabiliser leg downward movement is automatically stopped at a pre given force level To exceed this pre given force level operate the stabiliser leg down once again DANGER Always ensure that the stabiliser legs and stabiliser extensions are in working position and securely locked Place the extra support pl...

Page 58: ...stabiliser legs 1 Make sure the stabiliser extensions are extended a little 2 Unlock the stabiliser leg lock that holds the stabiliser leg in the transport position WARNING 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 For manual extensions lock the extension 6 Operate the stabiliser leg downwards...

Page 59: ...ight 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 Push the handle until the leg is pointing downwards DANGER Do not stand in the stabiliser leg tilting area 3 Lock the stabiliser leg with the handle 4 Extend the stabiliser extension For manual extensions lock the extension 5 Operate the stabiliser leg down...

Page 60: ...tabilis er leg Make sure that you have full control of the movement to avoid risk of crushing 4 Lock the stabiliser leg lock 5 Operate the stabiliser leg downwards until it is set to the ground 5 3 Operate the boom system out of transport position WARNING A crane with add on equipment can differ from the operations described in this sec tion For this reason study the operating in structions for ad...

Page 61: ...ting the crane to parking position When the angle ß is 135º between the horizontal and second boom the system doesn t allow to raise the second boom or to move extensions out in Push and hold the button 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 ...

Page 62: ...Operate the second boom fully against the underside of the first boom 2 Raise the first boom 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 4 Slew the crane to working position The crane is ready for use ...

Page 63: ... It creates a virtual cage around the area where the crane operator stands while manually operating the crane 6 1 2 APO Automatic power off APO is a function which automatically switches off the power to the control system It consists of 1 Timeout controlled power off 30 minutes by default 2 Parking brake controlled power off Through the vehicle s parking brake APO offers a safety function which e...

Page 64: ...y 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 lamps light up If the sensors indicate a positive pressure the lifting capacity is increased during the com plete lifting cycle 6 1 5 Slewing sector option Within slewing sector lifting capacity can be reduced due to stability The ...

Page 65: ...able to retract the extensions 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 6 2 2 To release OLP If all functions have been blocked due to OLP it is possible to temporarily release OLP and oper ate an appropriate crane function to correct the overload situation OLP release is active in 5...

Page 66: ...s The cylinder pressure LEDs on the user interface perform a running light The LED for padlock symbol will blink red 6 3 Manual extensions option Operation with manual extensions Always extend the hydraulic extensions first then the manual extensions The use of manual extensions should be restricted to the longest outreach needed When this reach is not needed the manual extension should be retract...

Page 67: ...ed Each manual extension has a sign 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 ho...

Page 68: ...witch 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 The LED for lights up on the user panel De activate Push the button again The LED for goes out ...

Page 69: ...hange from hoist to hook oper ation 1 Remove the counterweight Remove the locking pin the nut and the pin Release the rope 2 Remove the rope from the top roller Remove the locking pin the roller and the securing pin Pass the rope through the top roller ...

Page 70: ...ope 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 Remove the locking pin the clevis pin and the wheel Fit the rope end in the shackle ...

Page 71: ...uide from the first extension Remove the locking pin and the clevis pin 6 Remove the rope guide from the 4th exten sion Remove the locking pin the nut and the shaft 7 Remove the top roller and fit the hook WARNING To prevent injury hold the top roller firmly in your hand while demounting it ...

Page 72: ...72 During operation Operator s Manual GB 6 4 Remove the locking pin the nut and the shaft Put the hook in place and fit the shaft Tighten the nut Secure with the locking pin ...

Page 73: ...g in structions for any add on equipment care fully DANGER Always operate the crane manually from the position indicated in the figure 7 1 1 Operate the boom system 1 Retract the boom extensions completely NOTE If the crane is equipped with OPS push and hold button on the user panel while carrying out instructions 2 5 2 Slew the crane until the positioning arrows on the crane base and column align...

Page 74: ...m until the 2nd boom is horizontal Extend the extensions until the catcher drops Retract the extensions carefully to give the required parking width and the catch secures the boom Continue to lower the boom system onto the parking support Other cranes Continue to lower the boom system onto the parking support 5 Lower the 1st boom until it is secured on the parking support 6 Lower the 2nd boom unti...

Page 75: ...rating 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 For auxiliary stabiliser system option Repeat the process DANGER Always ensure that the stabiliser legs and the stabiliser extensions are in transport position and securely locked before moving the vehi cle Activate stabiliser oper...

Page 76: ...ing injuries Always keep hands away from moving parts during operation Manual tiltable stabiliser legs 1 Raise the stabiliser leg completely 2 Unlock the stabiliser leg lock 3 Tilt the stabiliser leg manually 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 ...

Page 77: ...t 4 Push the leg up until it reaches parking position 5 Lock the stabiliser leg 6 Retract the stabiliser extension completely DANGER Risk of crushing injuries Always keep hands away from moving parts during operation Mechanically controlled tiltable stabiliser legs 1 Raise the stabiliser leg so it is just free of the ground 2 Unlock the leg Raise the stabiliser leg When 200 mm remains the leg will...

Page 78: ... vehicle For auxiliary stabiliser system option Repeat the process Manually controlled stabiliser extensions Unlock the handle Take a firm grip around handle and push to retract the stabiliser extension and lock with the han dle Make sure the catcher is securely locked Hydraulically controlled stabiliser exten sions Retract the stabiliser extensions with the levers on the valve or the controller d...

Page 79: ...ge the PTO 7 4 Emergency operation Valve V30 EMERGENCY operation to bring the crane to parking position Do like this On the main 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 1 Break the security sealing on the dump valve ...

Page 80: ...trol 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 security seal wire has been broken 1 Break the security seal wire and remove the cap on dump valve 1 2 Press the dump valve button to the bottom and keep it in this position while you operate the crane to ...

Page 81: ...this position while you operate the stabiliser extensions and stabililiser legs to parking position using the levers on the stabiliser valve If separate stabiliser valve with remote con trolled stabiliser extensions and stabiliser legs 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...

Page 82: ...crane height exceeds a predetermined maximum and when the manual operated stabiliser extensions tiltable stabiliser legs are not locked in the transport position The audible warning can 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 and operate the crane into transport p...

Page 83: ...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 84: ...nes when 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 stil...

Page 85: ...ection and maintenance Maintain lifting accessories according to the supplier s instructions WARNING Ensure that faults in the crane are cor rected immediately Never correct faults yourself that may only be corrected by a HIAB service workshop Carry out yourself only the service and maintenance work you have the requisite knowledge and experience of If the crane is not to be used for 1 month or lo...

Page 86: ...ter Safety precautions and warn ings under section Signs on the crane Make sure that all the signs shown in section Signs on the crane are in position and in good conditions Make sure that all the symbols on your crane are in good conditions Locking devices Make sure that the locking devices are un damaged and working properly Make sure that the locking devices are prop erly locked Shafts shaft lo...

Page 87: ...HIAB service workshop Hooks Before every lift Check general condition of the hook and parts of the hook for deformation and surface damages with significant depth Check for damage to the hook structure e g any formation of cracks Check that the latch closes entirely Check that the shaft and the locking pin are in place Check that the plane bearing or the swivel are in good conditions DANGER In the...

Page 88: ...les how to handle this in section Check rope Check cables cable connections rope guides and the attachment points Polyamid parts as well as all bolt components have to be checked and must be replaced in case of wear and tear Electronic components Check that these are in good condition LED test To do the test 1 Push the ON OFF button for at least 2 sec The test is activated and all the red LEDs are...

Page 89: ...position while checking the oil Oil level on the slewing housing Do a check of the oil level in the slewing housing If necessary fill to correct level Filters Check the filter indicator If red replace the cartridge 8 3 2 Monthly inspection and mainte nance In addition to the daily inspection carry out the following each month Piston rods In cases where the cylinder piston rod is exposed to polluti...

Page 90: ...ubrication 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 Or have the oil tested by a workshop or specialist Add on equipment etc Maintain all add on equipment auxiliary equipment etc according to the instructions supplied with it Hoist Visua...

Page 91: ...being used in hot climates the oil might need to be changed more often Slewing housing Change oil in the slewing housing Hoist Change the gear oil in the drum Inspect the braking system 8 3 4 Hoist maintenance Interval Action Operating material At every use Visual and acoustic check up of the complete hoist system After every use Visual control of the rope Visual control of leaks Once a week Check...

Page 92: ...ear oil SAE 80W 90 Every 3 months Gear oil control After 1000 op erating hours latest after 1 year Change of gear oil Once a year Check up of braking system Complete hoist system Expert When the rope must be discarded see Check rope Use orginal rope see Change of rope You have to find out reason which leads to a loss of oil and the repair has to be done by experts ...

Page 93: ...e nominal diameter by more than 10 corkscrew type deformation kinked rope contrac tioned rope flattening rope loop formation of wires on the rope knots on the rope splicing on the rope basket formation on the rope loose wires in the rope individual wire breakages WARNING A rope has to be discarded when there are number of ruptures in the outer layers according to DIN 15020 ISO 4309 2 ruptures on a...

Page 94: ...urse 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 type rope Ø mm possible hoisting force kN 1st layer 4th layer TC1 8 11 5 9 5 TC2 TC2 L 10 24 18 TC3 14 12 39 39 30 xx TC5 14 16 54 54 43 xx NOTE When choosing a rope under all circumstances the stand...

Page 95: ...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 3 Detach the rope wedge 4 Pull out the rope from the rope inlet 5 Guide the rope out of the rope guide s and top roller 6 Discard the rope ...

Page 96: ... rope pocket Pay attention that the rope with rope wedge are perfectly clamped in the rope pocket 3 Spool on the rope In order to achieve a high spooling quality and durability the rope always has to be spooled on with a minimum hook load according to the following table Hoist type Minimum hook load TC1 40 80 kg TC2 TC2L 70 140 kg TC3 150 300 kg TC5 200 400 kg As a basic rule we recommend 5 of the...

Page 97: ...east every 6 months Under following conditions it is necessary to inspect wearing parts at a higher frequence than normal maintenance inspection intensive use mainly operation on the top rope layer rough environmental conditions sand dust etc Changing of the wear pad Remove the screws and the wear pad from the clamp Fit the new wear pad and secure with the screws 8 4 Lubrication WARNING Follow the...

Page 98: ...es 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 8 4 1 Lubrication schedule Lubricate after every 16 hours of use Lubricate after every 50 hours of use ...

Page 99: ...lubricating 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 4 3 Lubrication of the column bear ings Cranes up to X 072 DANGER The column bearings must be lubricated while the crane is slewed If one person lubricates the column bearings whil...

Page 100: ...f the hook cannot rotate easily without load 1 Lubricate the plane bearing surfaces Use a heavy duty penetrating spray grease type ZEP 2000 or equivalent quality Hooks with swivel Lubricate if the swivel cannot rotate easily 1 Remove the screw and mount a grease nipple 2 Add grease until grease appears be tween house and shank 3 Mount the screw Use a bearing grease type Texaco Multifak EP 2 or equ...

Page 101: ...anging oil in the slewing housing Change the oil in the slewing house yearly 1 Use a container with sufficient capacity to receive the oil Drain off the oil through the drain plug 2 Refill through the hole for the measuring stick with transmission oil of type MIL L 2105C or API GL 5 viscosity SAE 80W 90 cleanliness NAS 1638 8 3 Slew the crane after filling to the end positions three times 4 Check ...

Page 102: ...alation of oil mist a mask as well Inhalation of oil mist Contact a doctor Skin contact Remove polluted clothing wash with soap and water In the event of high pressure injection of the product see a doctor without delay Eye contact Rinse eyes with plenty of water see a doctor if irritation persists 2 Drain the oil tank through the drain plug Make sure the system contains as little as possible Use ...

Page 103: ...for HIAB products must comply with one of the following standards or equivalents ISO 11158 HV DIN 51524 part 3 HVLP ISO 6743 4 L HV Suppliers of hydraulic oil must verify that the quality and performance of the oil complies with the above standards When changing from mineral oil to a non polluting synthetic oil or when changing to biodegradable oil contact a HIAB service work shop ...

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: ...ch hydraulically operated piece of add on equipment at least twice to its end positions slowly 8 5 5 Replacement of filters WARNING High pressure temperature hazard Whenever work is carried out on the filters be prepared for hot oil to escape which can cause injury NOTE Only filter cartridges from Hiab must be used If non Hiab supplied cartridges are used warranty claims will be void The hydraulic...

Page 106: ...urs or once a year during regular service Main control valve V80R High pressure filter Located at the crane base connected to the pressure line from the pump Pressure reducer filter only remote con trolled cranes External filter located before the main control valve regardless of whether the stabiliser system is remote controlled or not Return filter Located in the oil tank 8 5 6 Replacing the car...

Page 107: ...r and clean or dispose of it in accordance with environmental regula tions 5 Remove the filter cartridge Examine the surface of the cartridge for dirt residue and larger particles these can indicate damage to the components 6 Clean the filter housing 7 Examine the filter housing and head seg ment especially sealing surfaces and thread for mechanical damage 8 Always replace the O ring of the filter...

Page 108: ...t clean the filter Replace the breathing filter of the filler cap at the same time as the return filter cartridge 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 ...

Page 109: ...6 Examine the filter housing for any possible mechanical damage 7 Replace the filter cartridge with a new one 8 Remove old O rings and replace oil before assembling 9 Place the filter cartridge carefully into the filter housing and screw Pay attention to the position of the handle 10 Install the filter cartridge with attached filter housing 11 Refit the cover 12 Replace the breathing filter in the...

Page 110: ... mixed with synthetic oil Gear oil control The hoist should be in horizontal position Turn the screw to check if oil is leaking If no oil is leaking corresponding oil has to be filled in through the filling screw When there is sufficient gear oil in the drum firmly tighten the screw again ...

Page 111: ...s access to the screw Turn the drum and open screws and Guide the gear oil from screw into a suitable container Fill in oil Turn the drum until the screw is on top of the drum Fill new gear oil through the opening of screw until some gear oil slightly overflow through the opening of screw Firmly tighten screws and TIP These filling amount can be less than indicated filling amount since oil remains...

Page 112: ...scription Components Fuse Location 2 Check all the cable connections Description Components Fuse Location System main fuse Relay Box Standard Box Oil Cooler 40 A Located on the vehicle were the crane is mounted Fuse for all components controlled by the relay box Hydraulic main control valve stabiliser leg warning lamp user interface MUX box Truck warning inter face Work lights 15 A Located inside ...

Page 113: ...the truck The hydraulic pump makes a noise Warning Stop us ing the crane immediately Oil tank filler breather is clogged 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 Hydraulic pump is faulty Go to a HIAB service work shop Leak on hydraulic system leaking coupling hose or line Danger Keep away from any oil l...

Page 114: ... housing Top up the oil in the slew ing housing to the required level The upper slewing bearing is not properly lubricated Lubricate the bearing The bearings in the slewing housing are damaged Go to a HIAB service work shop Irregular slewing move ments and unusual noises in cranes with continuous slewing system Insufficient oil in the hy draulic system Top up the oil tank Insufficient oil in the g...

Page 115: ...d boom damaged Go to a HIAB service work shop Cylinder internal leakage Go to a HIAB service work shop Boom extension cylinders do not follow the sequence Cylinder internal leakage Go to a HIAB service work shop Boom extensions shake dur ing extending retracting function Cylinder internal leakage Go to a HIAB service work shop Sequence screw in cylinder head loose Tight the screw in the right posi...

Page 116: ...oggle button Press to toggle between menu items OK button Press to select item Menu items Error codes If item Error codes is selected and there are errors present in the system the screen will show a three digit number for each fault in the system Timers Counters When item is selected information is shown about Total time Number of hours that the crane has been engaged Use time Number of hours tha...

Page 117: ...ors 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 The different sec tors are marked in colors green yellow grey or red where green indicates the highest percentage of lifting capacity and red indicates the lowest percentage ...

Page 118: ...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 119: ...from the slewing system solid lubricants greases from the joints and journal bearings other waste containing oils and greases hy draulic oil filters European Union Disposal Information This symbol identifies the parts of your crane that need to be disposed of separately from household waste according to EU legislation When one of this part reaches the end of its life take it to a collection site d...

Page 120: ... 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 10 3 Theoretical using time Hoist Drive group 1Bm class of operating time T3 theoretical using time years 12 8 6 4 at an average daily operat time h 0 5 1 0 calc total operating time h 1600 load spectrum L2 hours of full line p...

Page 121: ...which are individually valid for hoisting and pulling units have to be fol lowed 10 4 Performance Data TC1 rope ca pacity Rope diameter 8 mm Rope capacity according to DIN 15020 Grooved drum Rope layer 1 2 3 4 Hoisting force in kN 11 5 11 10 9 5 Rope lenght in m layer rope diameter 8 mm 10 12 12 13 4 Total rope length in m 10 22 34 47 38 Rope speed v in m min with standard motor 42 46 50 54 Weight...

Page 122: ...zontal LSS V Load Stabilising System Vertical Load Stabilising System Vertical MEWP Mobile Elevating Work Platform Mobile Elevating Work Platform MSC Manual Speed Control Manual Speed Control MUX Multiplexer Box Multiplexer Box OLP Overload Protection Overload Protection OPS Operator Protection System Operator Protection System PFD Pump Flow Distribution Pump Flow Distribution PSB Power Supply Box...

Page 123: ...using 1 10 Oil level in the slewing motors 1 11 Oil level in the tank 1 12 Filters 2 FUNCTIONAL TESTS 2 1 Stop buttons 2 2 Levers 2 3 Controller 2 4 LED test 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 Permission to reproduc...

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