HIAB X-HiPro 358-408-418 X4 Operator'S Manual Download Page 43

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The HiPro system

Operator's Manual GB

4.3

Components of the HiPro system

①

Main control valve

④

Dump valve 1

⑦

Lamp pole [Option]

②

Stabiliser control valve

⑤

Dump valve 2

⑧

XSDrive controller

[Option]

③

User panel SPACE X4-UI

⑥

Pressure-reduc-

er filter

⑨

CombiDrive controller

[Option]

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

Page 1: ...This operator s manual is an Original Instruction and applies to cranes with serial number from 3580001 4080001 4180001 2018 01 Operator s Manual GB HIAB X HiPro 358 408 418 X4 ...

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: ...ding valves 18 2 8 Description of HIAB X HiPro 358 408 418 18 2 9 Accessories that can be fitted in a X HiPro 358 408 418 19 3 Safety precautions and warnings 20 3 1 Operating conditions 20 3 2 Wind speeds 21 3 3 Definition of a HIAB loader crane 22 3 3 1 Noise declaration 23 3 3 2 Signs on the crane 24 3 3 3 Maximum load AR 25 3 3 4 Maximum load moment 27 3 4 Signals when using a crane AR 29 3 5 ...

Page 4: ... 11 4 Standard functions and symbols 55 4 11 5 Battery and battery charger XSDrive 56 4 12 CombiDrive controller 57 4 12 1 Displays 58 4 12 2 Buttons 60 4 12 3 Menus standard functions and symbols 62 4 12 4 Battery and battery charger 66 5 Starting crane operation 67 5 1 Starting operations AR 67 5 2 Set the stabiliser system 69 5 2 1 Stabiliser system and ground conditions 71 5 2 2 Activate the s...

Page 5: ...rive 86 6 4 To release OLP 87 6 5 Manual extensions option 88 7 Ending crane operation 92 7 1 Operate the boom system into transport position 92 7 1 1 Operate the boom system 93 7 2 Placing the stabiliser system in the transport position 94 7 3 Switching off the control system 98 7 4 Emergency operation Valve V200 99 7 5 TWI Transport warning interface option 100 8 Maintenance and Service 102 8 1 ...

Page 6: ...tridge in pressure reducer filter V80R 118 8 5 4 Replacing the cartridge in high pressure filter 121 8 5 5 Checking the oil tank level 123 8 5 6 Changing the hydraulic oil 123 8 5 7 Bleeding air from the hydraulic system 126 8 6 Troubleshooting 126 8 6 1 Main fuses 126 8 6 2 Faults on the crane 128 8 6 3 Display option 131 9 Decommissioning 133 9 1 Decommissioning a crane 133 10 Technical Data 135...

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: ...tted depending on your crane configuration Manual extensions option Hoist option JIB 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 the crane base Continuou...

Page 13: ...tabiliser 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 2 4 Boom system The boom system consists of the following components 1st boom 2nd boom Hydraulic extensions The length of the hydraulic extension depends on the type of crane Manual extensions option Hook opt...

Page 14: ... advantage is that the hoist makes it possible to handle loads 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 P...

Page 15: ... following components JIB boom JIB cylinder JIB extension JIB extension cylinder JIB manual extension option JIB support JIB long support 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 Hooks option Different hooks can be mounted depending on the crane model DANGER Never exceed the maxi...

Page 16: ...16 Structure and parts of the HIAB crane Operator s Manual GB 2 5 Separate lifting accessories option Separate lifting accessories help to make or use a slinging device eye hooks shackles eye bolts etc ...

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: ...essure is re quired 2 8 Description of HIAB X HiPro 358 408 418 The HIAB X HiPro 358 408 418 are compact fully hydraulically operated goods cranes Lifting capacity HIAB X HiPro 358 33 6 tonne metres HIAB X HiPro 408 38 tonne metres HIAB X HiPro 418 39 6 tonne metres The crane is supplied in many versions from HIAB X HiPro 358 408 E 4 reach 11 8 me tres to HIAB X HiPro 358 408 E 8 reach 21 8 metres...

Page 19: ...e in combinations TC2 418 EP 2 3 4 5 TC2 TC2L Not compatible with manual extensions in 358 408 E 8 JIB70X 4 358 408 E 4 5 6 7 8 TC2L 358 408 E 5 6 JIB70X 3 4 TC2L 358 408 E 4 5 JIB 100X 4 5 TC2L Snatch block for TC2 and TC2L Available in all combinations except in the configuration 358 E 8 Manual extensions available in combinations 1 manual extension in crane 418 EP 5 1 358 408 E 8 1 1 manual ext...

Page 20: ... 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 21: ... 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 22: ...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 23: ...ich 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 Using the JIB upside down HiPro cranes except JIBs prepared for that See Operator s Manual for your JIB DANGER Lifting people with a crane is never allowed unless it is a MEWP crane 3 3 1 Noise declaration The following values for emitte...

Page 24: ...XX X XX X XX X XXXX XXXX XXXX XXXX XXXX XXXX XXXX XXXX XXXX XXXX XXXX XXXX XXXX XXXX XXXX XXXX XXXX XXXX XXXX XXXX XXXX XXXX XXXX XXXX XXXX XXXX XXXX XXXX XXXX XXXX XXXX XXXX XXXX XXXX XXXX XXXX XXXXX X X XXXXXXXX XXXX XXXX XXXX XXX XXXXXXXXX XXXX XXX XXXXXXXX XXXX XXXX XXXX Kg Kg XXXXXXXX XXXX XXXX XXXX XXX XXXX XXX Kg Kg XXXX XXXX XXXX XXXX XXXX XXX XXXXXX XXXXXXXX XXXX XXXX XXXX XXXX XXXXXXXX X...

Page 25: ...rating radius of the crane the lower the lifting capacity will be because of the weight of the boom system itself The load 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 hold...

Page 26: ...umn 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 crane The load curves show the maximum load that may be lifted at a given reach and height For a given maximum load the possible working zone is to ...

Page 27: ...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 first boom down up second boom down extension boom out If the second boom is down then the following movements are locked first boom up second boom up extension boom out first boom down certain crane types and cases L...

Page 28: ...nd four legged sling 0 45 1 4 2 1 45 60 1 0 1 5 If the angle between the legs of the sling exceeds 90 the slings should not be hung directly on the hook but rather be slung from a ring that is hung on the hook Working close to the load Always try to lift the load with the extension boom retracted however not completely The crane then has the greatest lifting capacity Place the vehicle as close as ...

Page 29: ...y use the first boom TIP Make smooth crane movements operate the crane with various functions simultaneously In this way you will also prevent the hydraulic system heating up quickly 3 4 Signals when using a crane AR DANGER If it is not possible to see the load and the entire working area clearly the crane oper ator is obliged to follow the instructions and signals given by a qualified person qual...

Page 30: ...d Lower Arm pointing downwards and index finger down Circular motion with hand Stop all crane movements Also Hold the load in position Raise the open hand with the palm clearly visible and arm at shoulder height Keep the hand still Emergency stop for all movements by the crane Raise the hands and the arms to an oblique angle ...

Page 31: ...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 the hands Open the grapple Extend the arms at shoulder height with the palms facing downwa...

Page 32: ...ple Move both hands close together Lift the open grapple a little Extend both arms at shoulder height with the palms facing upwards Make vertical movements with both arms outstretched Keep the grapple in position briefly Raise the hand drooping slightly with the fist clenched ...

Page 33: ...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 34: ...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 35: ...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 36: ...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 37: ...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 38: ...valve The PTO or power supply must be disengaged The operating system must be switched off Pay attention to the width and height of the crane in the transport position The crane has to stay within the width of the truck Make sure the stowed crane 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...

Page 39: ...zards 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 5 5 Use ...

Page 40: ... crane operation as follows After use always place the crane in the transport position Withdraw the stabiliser legs and stabiliser extensions Check that the locking mechanisms are properly locked 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 doin...

Page 41: ...nctions 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 On the crane there are various sensors and indicators which send signals about the crane s load position and movements to a cent...

Page 42: ...wer 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 works...

Page 43: ...ual GB 4 3 4 3 Components of the HiPro system Main control valve Dump valve 1 Lamp pole Option Stabiliser control valve Dump valve 2 XSDrive controller Option User panel SPACE X4 UI Pressure reduc er filter CombiDrive controller Option ...

Page 44: ...e 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 45: ...ered 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 46: ...heir speed When remote control is used the oil flow is allocated by means of PFD Standard functions and symbols The order of the functions is customized for each crane The image on the right shows an example of a main control valve func tions placed on the column 4 6 Different stabiliser control valves Different stabiliser control valves that you can find on cranes 2 function 4 function control va...

Page 47: ...iser extensions The driver must have full view when operating the stabiliser extensions outward Button is used for OLP release if the crane is in an OLP situation and for disconnecting the automatic dump function Stop button is pushed in an emergency Button Once the controller is activated this button can be used to sound the crane horn Button activates OLP for manual exten sions if fitted Button ...

Page 48: ... is active Remote control Green light on Remote control is active Green light flashing Button for remote control has been pressed waiting for connection to hand unit Red light on Radio interference Parking control Blue light on Slew is in parking position Service Green light on Service needed Red light on Error in the system Red light blinking Critical error Dump valve Blue light on Dump activated...

Page 49: ...pressure and thereby unnecessary 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 extensions and legs only when this valve is activated The dump val...

Page 50: ...ller XSDrive has either four or six levers or two or three joysticks for proportional func tions programmed in the different menu selec tions The controller normally communicates with the crane via radio but can also be operated via cable Radio communication is dependent on Transmitter fitted in the controller Receiver box fitted on the operating base The Receiver box consists of a combined radio ...

Page 51: ...r or receiver Connec tion is made between the controller and the receiver box Radio communication is auto matically disabled when the cable is connected 4 11 1 Indicator LEDs on XSDrive controller The indicator LEDs on the controller indicates button positions errors stability cylinder pres sure etc The appearance of the panel differs somewhat depending on if the controller has levers or joysticks...

Page 52: ...ashing 90 of maximum pressure Lower and upper LEDs red light 100 of maximum pressure Manual extension Green light on Manual extension activated ADC Green light on Increased capacity ADC mode Menu LEDs Light on Indicates active menu 4 11 2 Buttons ON OFF buttons Buttons for 7 extra ON OFF functions engine on off engine speed horn etc Menu selection Push to change between menus 1 to 4 OLP release Pu...

Page 53: ...s To release it turn the button clockwise Locking the controller 1 Push the stop button 2 Push and hold both arrows on the toggle button and release the stop button at the same time 3 The 4 LEDs flash at the same time Now you cannot operate the controller 4 Push the stop button Unlocking the controller 1 Make sure that you pushed the stop button 2 Push and hold both arrows on the toggle button and...

Page 54: ...IB hoist etc Menu 2 option If crane is equipped with extra remote controlled stabiliser system Menu 3 option Slewing attachment If crane is equipped with remote controlled stabiliser left and right stabiliser extension left and right stabiliser leg Menu 4 option Similar to menu 3 but for extra stabiliser legs ...

Page 55: ...ctions and symbols The function corresponding to each lever depends on the configuration of the specific crane The table below shows examples Controller XSDrive levers Controller XSDrive joystick 3 0 3 Controller XSDrive joystick 2 2 2 Controller XSDrive joystick 3 2 3 ...

Page 56: ...harger The battery charger is to be fitted in a protected environment preferably in the cab Two batteries are delivered with each unit one of which can always be placed in the charger LED is lit continuously when the battery charger is ready for use Place the battery in the charger LED flashes slowly during recharging and has a steady light when the battery is fully charged Charging time The norma...

Page 57: ... fitted in the controller Radio decoder fitted at the crane base Information can be sent both from and to the controller In the decoder radio there is a corre sponding unit which handles the traffic at the other end Cable connection A four metre cable is supplied as standard with The controller The cable is intended to be used for short term operation and when pairing in conjunction with the repla...

Page 58: ...nt where the tempera ture exceeds 10 C whenever not in use Centre display The center display provides information about which menu has been chosen as well as indicat ing for example radio reception battery status fault information ADC and VSL Indications on the centre display Error This symbol a spanner appears if the control system has discovered a fault in the system See section Buttons for erro...

Page 59: ...Indicates that MEWP mode if present is active JDC Indicates that the JDC function is active Signal strength The bars show the radio signal strength Five bars indicate opti mum reception If the symbol flashes the radio is connected but starting conditions are not met ADC Automatic Duty Con trol Indicates that the ADC function is active Battery capacity The battery symbol shows remaining power in th...

Page 60: ... each button is depending on the config uration of the specific crane Micro mode Push to choose micro mode Push again to choose normal mode Menu CRANE Push to choose menu CRANE Stop button Push to deactivate the controller Release to activate Menu EXTRA Push to choose menu EXTRA OLP release Push and hold to activate OLP release See section OLP re lease Menu ON OFF Push to choose menu ON OFF Manual...

Page 61: ...he control system are shown Horn Push to sound the horn Locking and unlocking the controller Locking the controller 1 Push and hold button and while the stop button is pushed 2 Keep button and pushed while pull ing out the stop button The centre display then shows a large locked padlock symbol Unlocking the controller 1 Push and hold button and while the stop button is pushed 2 Keep button and pus...

Page 62: ...the operator can step through submenus by pushing the menu button repeatedly Each function is operated using a specific lever If a lever is faulty or moved at startup the lever and the function is disabled The other levers works as normal With the 2 extra levers on the 8 lever controller it is possible to use the seventh and eighth functions simultaneously with func tions 1 6 without shifting CRAN...

Page 63: ...1 2 3 63 The HiPro system Operator s Manual GB 4 12 3 CRANE MENU Left side display Centre display Right side display Example of submenus for the 8 lever controller ...

Page 64: ...Manual GB 4 12 3 CRANE MENU Left side display Centre display Right side display EXTRA menu button The EXTRA menu contains hydraulically propor tional functions for example front and rear stabi liser extensions and legs boat supports bunk shifting etc ...

Page 65: ... stabiliser extension out in Auxiliary stabiliser extension out in Auxiliary stabiliser extension out in ON OFF menu button The ON OFF menu includes functions such as engine start stop and throttle The functions are shown as text instead of symbols in the displays A lever may be moved in any direction in order to activate the corresponding function Examples of the left side display Centre display ...

Page 66: ...rger The battery charger is to be fitted in a protected environment preferably in the cab Two batteries are delivered with each unit one of which can always be placed in the charger Normal charging time for a flat battery is approximately 3 hours Operating ambient temp Battery 0 to 45 C Display A lights when the charger is activated and lights during charging and lights when the battery is fully c...

Page 67: ...ddle of the gauge the crane is in 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 and or JIB MEWP applications the vehicle has to be completely levelled in any direction...

Page 68: ...p To start the control system press the On Off button on the user panel The LED above the button starts to lights up The system will check itself 2 4 seconds Start the controller 1 Fasten the controller to a waist belt or shoulder neck strap in the most comfort able operation position The Stop button should be on the right hand side 2 Press the button The LED above that button gives a steady light...

Page 69: ...s and legs must be fully extended and set to the ground without lifting the wheels from the ground Cranes with VSL when the stabiliser exten sions are not fully extended the lifting capac ity is optimized by the VSL function to ensure the maximum stability of the vehicle Cranes without VSL crane must be operat ed with the stabiliser extensions fully ex tended and the stabiliser legs set to the gro...

Page 70: ... be operated As soon as the button has been pushed the LED for the active stabiliser leg will light green Cranes with VSL the stability sector LEDs will indicate the crane capacity in six differ ent sectors due to stability The stability sector indication will change according to the stabiliser system position Cranes without VSL the stability sector LEDs will light green regardless of the situa ti...

Page 71: ...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 Crane Model P KN 265 285 108 358 398 408 418 236 410K 164 528 548 558 638 658 247 322 377 328 352 362 388 224 858 1058 368 422 477 395 425 335K 435K 230 Auxiliary stabilisers 205 DANGER Check that the extra support plates do not bend or sink into the ground Do ...

Page 72: ... panel 2 Select the menu for stabiliser system on the controller 3 On the side where the stabiliser extensions are to be operated outwards push the button to activate stabiliser system operation and confirm the view The stabi liser legs can be driven up and down regardless of the side 5 2 3 Extend the stabiliser extensions The procedure of setting the stabiliser extensions differs depending on the...

Page 73: ...iguration DANGER Do not stand in front of the hydraulically operated stabiliser legs when you are operating them 5 2 4 Set the stabiliser legs AR The procedure of setting the stabiliser system differs depending on the type of stabiliser system Repeat the instructions for the stabiliser extension and leg on the other side of the vehicle For auxiliary stabiliser system option Repeat the process WARN...

Page 74: ... again DANGER Always ensure that the stabiliser legs and stabiliser extensions are in working position and securely locked Place the extra support plates Place the extra support plates under the stabiliser leg plates DANGER Check that the support plates do not bend or sink into the ground Non tiltable stabiliser legs 1 Make sure that the stabiliser extensions are extended 2 Operate the stabiliser ...

Page 75: ...Unlock the stabiliser leg lock that holds the stabiliser leg in the transport 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 For manual extensions lock the extension 6 Operate the stabiliser leg downwards until it is set to the ground ...

Page 76: ...andle 4 Extend the stabiliser extension For manual extensions lock the extension 5 Operate the stabiliser leg downwards until it is set to the ground Mechanically controlled tiltable stabiliser legs AR 1 Make sure the stabiliser extension is ex tended a little and the stabiliser leg can be rotated freely of the vehicle 2 Unlock the stabiliser leg lock 3 Use the stabiliser leg lever to tilt the sta...

Page 77: ...ne with add on equipment can differ from the operations described in this sec tion For this reason study the operating instructions for any add on equipment carefully Always ensure that the stabiliser exten sions and legs are in working position and securely locked before operating the boom system out of parking position ...

Page 78: ...e image 1 If the stabiliser system is manually con trolled push button on the user panel to activate remote control 2 If using remote control push button on the controller to change the menu into crane operation NOTE As soon as you have selected remote control operation it is no longer possible to operate the main control valve levers ...

Page 79: ...he 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 Press the button for release 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 th...

Page 80: ...tact between the tip of the pin A and the parking support B as shown in If needed move the second boom against the first boom slowly CAUTION Take care not to damage the parking pin and parking support during these operations 4 Extend the first extension until parking pin A comes free of the parking support B and plate C is shown 5 Raise the second boom CAUTION Pay careful attention not to damage t...

Page 81: ...ill light continuously By pushing the button again the crane returns to full speed and the LED goes out When pushing the speed selector button all levers must be in neutral NOTE The crane speed will depend upon the crane functions you are using and how many crane functions you operate at the same time 6 1 2 Controlling the crane speed with the controller CombiDrive At startup the crane speed is se...

Page 82: ...t 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 ensures that the control system is off when the vehicle is moving When parking brake is released the control system receives a signal and shuts OFF For emergency operation During 5 seconds it is possible to activate the control system by pushing t...

Page 83: ...tive 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 sensors indicate a positive pressure the lifting capacity is increased during the com plete lifting cycle 6 1 8 PFD Pump flow distribution Whe...

Page 84: ...e LSS V when working in confined spaces Compensating movement can cause the crane to collide with obstacles If the function LSS V is active when SPACE is switched off the function will be active when SPACE is started again Activate and deactivate LSS V By default with the controller XSDrive Push button to activate and button to deactivate Activate and deactivate LSS V By default with the controlle...

Page 85: ...r lamp will light continuously The pressure level in the first and second boom is indicated by the LEDs on the user interface 50 of maximum pressure 1 of 4 LEDs light green 70 of maximum pressure 2 of 4 LEDs light green 90 of maximum pressure 3 of 4 LEDs flash red 100 of maximum pressure 4 of 4 LEDs flash red NOTE Do not operate heavy loads with the extensions fully retracted In an OLP situation i...

Page 86: ... pressure in the cylinders is shown on the displays When 50 or more of maximum pressure is reached the percentage alternates with the function symbol once a second in the display corresponding to each lever The display shows 50 70 90 and 100 as the pressure increase When pressure reaches 100 all functions that would increase pressure are blocked If the operator attempts to operate a blocked functi...

Page 87: ...time can be operated Extension out cannot be operated at all The 5 second interval starts to count down as you move the lever DANGER Only use the OLP release to get the crane out of a locked position Never use the OLP release to overload the crane deliberately OLP release on user panel Push and hold button on the user panel whilst operating load reducing functions The cylinder pressure LEDs on the...

Page 88: ... to the longest outreach needed When this reach is not needed the manual extension should be retracted DANGER Do not stand in front of moving parts They may eventually move and cause injuries To extend the manual extensions 1 Locate the boom system as close as possible to the horizontal position but low enough to reach the extension by hand 2 Stop the crane by pressing the stop button 3 Remove the...

Page 89: ...on 3 Remove the locking device and the locking pin 4 Retract the manual extension fully by hand 5 Secure the manual extension by locking the pin and locking device DANGER Make sure that the locking device is properly locked Activate and de activate OLP for manual ex tensions on the user panel WARNING You must switch the OLP on and off manually for additional manual extensions Activate Push button ...

Page 90: ... You must switch the OLP on and off manually for additional manual extensions Activate Push buttons and on the controller The manual extensions are now included in the OLP protection The lifting capacity will be reduced automatically The lamp for lights up on the user panel De activate Push the buttons again The lamp for goes out ...

Page 91: ... manual extensions Activate Push both button and 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 92: ...n differ from the operations described in this sec tion For this reason study the operating in structions for any add on equipment care fully DANGER During folding of the boom system always operate the crane manually from the posi tion indicated in the figure With remote controlled cranes stay in a safety area while the boom system is moving ...

Page 93: ...second boom to vertical posi tion as shown in the figure To be able to lock the extensions slide out the first extension about 500 mm until plate B is shown CAUTION Pay careful attention not to damage the slew ing motors 5 Adjust the second boom and retract the first extension slowly to ensure that the extension C is locked by the parking support D CAUTION Take care not to damage the parking pin a...

Page 94: ...eg 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 Manually controlled crane Activate stabiliser system operation on the user panel by press ing button Remote controlled crane Manually controlled stabiliser s...

Page 95: ...tion Operator s Manual GB 7 2 Non tiltable stabiliser legs 1 Raise the stabiliser leg 2 Retract the stabiliser extension completely DANGER Risk of crushing injuries Always keep hands away from moving parts during operation ...

Page 96: ... 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 DANGER Risk of crushing injuries Always keep hands away from moving parts during operation ...

Page 97: ...eep hands away from moving parts during operation Mechanically controlled tiltable stabiliser legs AR 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 start to tilt upwards 3 Lock the stabiliser leg lock 4 Retract the stabiliser extension completely DANGER Risk of crushing injuries Always keep hands away from mov...

Page 98: ...tion Make sure that the stabiliser locking device option is securely locked WARNING Always ensure that the stabiliser legs and stabiliser extensions are in transport position and securely locked 7 3 Switching off the control system Switch off the control system with the on off button If you are using the remote controller Push the stop button on the controller and switch off the control system Dis...

Page 99: ...ays go to contact a HIAB service work shop when the seal wire has been broken 1 Engage the pump 2 Break the security sealing on Dump valve 1 on the supply unit 3 Use a screw driver or similar and push the knob on Dump valve 1 4 Check that no unintended movements starts If you get unintended movements then release the knob and contact HIAB service 5 Push the dump valve button and turn 90 degrees un...

Page 100: ...ve 2 on the supply unit 3 Check that no unintended movements starts If you get unintended movements then release the knob and contact HIAB service 4 Push the dump valve button and turn 90 degrees until it is blocked 5 Operate the stabiliser extensions and stabi liser legs to parking position using the levers on the stabiliser control valve 7 5 TWI Transport warning inter face option WARNING If you...

Page 101: ...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 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 lo...

Page 102: ...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 103: ...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 104: ...pection 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 l...

Page 105: ...pter Safety precautions and warnings 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 condi tions 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 l...

Page 106: ... 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 th...

Page 107: ... is equipped with warning lights lamp pole lamps will come on 2 Release the button After 3 sec all the green the LEDs are illuminated The test is finished when all LEDs is extinguished Hydraulic system Check that there are no leaks from the hydraulic hoses lines and connections Make sure that all security seal wires Ex LHV dump valves etc are not broken Always go to contact a HIAB service work sho...

Page 108: ...shes Inspect all the pivot pins and bushings for the crane boom and cylinders for damage play etc Bolts and screw fixings Check that bolt and screw fixings are not loose If loose contact a HIAB service work shop Cables and sensors Check that these are in good condition Lubrication schedule Carry out the lubrication according to the instructions Slewing bearing Upper column bearing Check that the s...

Page 109: ...c oil Change the hydraulic oil Or have it tested by a workshop or specialist Oil in the slewing gear boxes Change the oil in the slewing gear boxes Or have it tested by a workshop or specialist Hydraulic system oil tank filler cap Change the filler cap Replace filters Slewing bearing Check the tightening torque The bolts must be carefully retightened to the torque value recommended in the technica...

Page 110: ...ou can cause serious damage to the crane and to add on equipment Type of grease Use lithium based grease containing EP additives consistencies 2 and 3 are recommended depend ing on the climate Recommended greases BP LS EP 2 ESSO UNIWAY EP2 N AGIP GR MU EP3 NYNÄS UNIFETT EP NOTE Avoid grease with graphite or molybdenum disulphide additives ...

Page 111: ...111 Maintenance and Service Operator s Manual GB 8 4 1 8 4 1 Lubrication schedule AR Lubricate after every 16 hours of use Lubricate after every 50 hours of use Grease after every 50 hours of use ...

Page 112: ...orking condi tions Change the oil at least once a year Refill with oil SAE 80W 90 NOTE Remove the plug and before replacing oil drain all oil from gear case flush carefully the internal side of the gearbox with the appropriate washing compound Refill through plug 8 4 3 Lubrication of the slewing bear ing Remove cover Check that there is enough lubrication film grease if necessary Grease through th...

Page 113: ...393 K 20º to 120º Viscogen 0 238 K to 398 K 35º to 125º EPEXA 2 243 K to 393 K 30º to 120º CADREXA GR 1 AL 243 K to 393 K 30º to 120º BEACON EP2 248 K to 403 K 25º to 130º Esso Multi Purpose Grease Moly 248 K to 423 K 25º to 150º CENTOPLEX 2 EP 253 K to 403 K 20º to 130º GRAFLOSCON C SG 0 plus 243 K to 473 K 30º to 200º Mobilux EP 2 253 K to 393 K 20º to 120º Mobiltac 81 243 K to 393 K 30º to 120º...

Page 114: ...blies approxi mately every 100 working hours Lubrication is made by injecting 5 cm3 approximately into each grease nipple around the bearing Grease to be used is marked in table Bearing should be rotated during lubrication The grease filling is there to reduce friction seal the bearing and provide protection against corrosion Before and after prolonged stop of the crane lubrication is absolutely n...

Page 115: ...es 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 Recommended greases Upper lower slide pads Black White colour BP LS EP 2 ESSO UNIWAY EP2 N AGIP GR MU EP3 NYNÄS UNIFETT EP Upper lower slide pads Grey P...

Page 116: ...il grease appears be tween house and shank 3 Mount the screw Use a bearing grease type Texaco Multifak EP 2 or equivalent quality 8 5 Hydraulics 8 5 1 Replacing the cartridge in return oil filter Return oil filter with clogging indicator NOTE Do not 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 f...

Page 117: ... indicate damage to the components 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 ...

Page 118: ...the old O ring and replace it with the supplied one oil it before assembling 5 Remove the filter cartridge Examine the surface of the filter cartridge for dirt residue and larger particles these can indicate dam age to the components 6 Clean the filter housing 7 Unpack the new filter cartridge Make sure that it is clean and screw carefully 8 Remount the filter housing and tighten it torque 40 60 N...

Page 119: ...gula tions 5 Remove the filter cartridge Examine the surface of the filter 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 housing 9 Oil the threads and sealing surfaces on the fi...

Page 120: ...80R main control valve 1 Switch off hydraulic system Release filter from pressure 2 Clean the immediate surrounding area of the outlet section of the stabiliser control valve s 3 Remove the plug using a 6 mm hexagonal wrench 4 Remove the spring together with the filter from the hole 5 Examine the surface of the filter for dirt residue and larger particles these can indi cate damage to the componen...

Page 121: ...21 Maintenance and Service Operator s Manual GB 8 5 4 8 5 4 Replacing the cartridge in high pressure filter High pressure filter Optical indicator Cartridge WARNING Dirt will damage the hydraulic system ...

Page 122: ...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 123: ...e in the parked position Take care that the temperature of the oil does not exceed the point where you can handle it safely If this occurs allow the oil to cool before moving to the next step WARNING Suitable eye and hand protection must be worn while carrying out this operation and if there is a risk for inhalation of oil mist a mask as well Inhalation of oil mist Contact a doctor Skin contact Re...

Page 124: ...draulic oil The oil used for filling must be clean Do not mix different oils Hydraulic oils must have been dealt with accord ing to cleanliness requirements ISO 4406 16 13 Hydraulic oil that is approved for HIAB products must comply with one of the following standards or equivalents ISO 11158 HV DIN 51524 part 3 HVLP ISO 6743 4 L HV Suppliers of hydraulic oil must verify that the quality and perfo...

Page 125: ... 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 126: ...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 8 6 Troubleshooting 8 6 1 Main fuses If the microprocessor detects a fault this must be rectified immediately Fault Probable cause Action The control system does not work at all The indicator light next to On Off button on the user panel...

Page 127: ...trol user panel MUX box Truck warn ing interface Work lights 15 A Located inside the relay box Fuse for all components connected to the stan dard box Hydraulic main control valve stabiliser leg warning lamp user pan el MUX box Truck warning interface 10 A Located inside the stan dard box 8 6 1 1 Main fuses CD Description Components Fuse Location Fuse for all components controlled by the radio deco...

Page 128: ...nic system will not start Parking brake on the truck is not engaged Engage parking brake on 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...

Page 129: ...port cylinders do not turn Three way valve failure Go to a HIAB service work shop Irregular slewing move ments and unusual noises in cranes with rack and pinion slewing system Insufficient oil in the hy draulic system Top up the oil tank Insufficient oil in the slew ing housing Top up the oil in the slew ing housing to the required level The upper slewing bearing is not properly lubricated Lubrica...

Page 130: ...act a HIAB service workshop Cane performance when op erating it with the controller is unsatisfactory The pressure reducer filter is clogged Replace the pressure reducer filter Boom system cannot keep the load height and it goes down by itself Load holding valves on the first boom or second boom damaged Go to a HIAB service work shop Cylinder internal leakage Go to a HIAB service work shop Boom ex...

Page 131: ...shop 8 6 3 Display option The display has three menu items Error codes Timers Counters and VSL These items are shown on the screen when the display is first engaged To be able to select an item push the menu toggle button or the OK button In the bottom left of the screen the name of the item currently highlighted is shown Buttons Push to go back to main menu Push to go back one step Push to toggle...

Page 132: ... sectors surround ing the crane and in each sector a percentage is shown A percentage of 90 indicates that the working pressure is reduced to 90 in this sector to guarantee full stability The different sectors are marked in colors green yellow grey or red where green indicates the highest percentage of working pressure and red indicates the lowest percentage Function indication If function LSS V i...

Page 133: ...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 134: ...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 135: ... specific crane The enclosed Technical Data printed out by the installer should be stored together with this Operator s manual 10 2 Identification of the loader crane The information below is to be filled in by the installer The same information will be found on the serial number plate on the crane Mark HIAB Type Serial number Manufact year ...

Page 136: ...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 137: ...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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