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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 is not lit,

even if you push On/Off.

Defective

fuses.

1. Replace faulty fuses in the:

- vehicle
- standard box
- relay box
(See Description, 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,

Remote control, user panel,

MUX box. Truck warning

interface, Work lights.

15 A

Located inside the

relay box (1).

Fuse for all

components

connected to the

standard box.

Hydraulic main control valve,

stabiliser leg warning lamp, user

panel, MUX box. Truck warning

interface.

10 A

Located inside the

standard box (2).

Maintenance and Service

104

HIAB K-HiPro 285-425 X4

Содержание K-HiPro 285-425-4 Series

Страница 1: ...HIAB K HiPro 285 425 X4 Operator s Manual GB This operator s manual is an Original Instruction and applies to cranes with serial numbers from 2851001 4250001 2018 12 ...

Страница 2: ...elf 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 suggestions...

Страница 3: ...ad AR 19 3 3 4 Maximum load moment 21 3 4 Signals when using a crane AR 23 3 5 Use of the crane 26 3 5 1 Preparations for use 28 3 5 2 Crane operation 29 3 5 3 Driving with the crane 32 3 5 4 Use of lifting equipment 33 3 5 5 Use of demountable cranes 33 3 5 6 Ending crane operation 34 4 The HiPro system 35 4 1 Control System SPACE X4 35 4 2 How the safety system works 35 4 3 Components of the HiP...

Страница 4: ... function 72 6 1 7 ASC Automatic Speed Control 72 6 1 8 ADC Automatic Duty Control 73 6 1 9 PFD Pump flow distribution 73 6 1 10 Slewing sector option 73 6 1 11 VSL Variable Stability Logic option 74 6 1 12 VSL Variable Stability Logic Plus option 74 6 1 13 LSS V Load stabilising system vertical Option 75 6 2 OLP Overload protection 75 6 3 OLP indications on the controller 77 6 4 To release OLP 78...

Страница 5: ...e in high pressure filter 101 8 5 7 Replacing the cartridge in pressure reducer filter V200 102 8 5 8 Replacing the cartridge in return oil filter 103 8 6 Troubleshooting 104 8 6 1 Main fuses 104 8 6 2 Faults on the crane 105 8 6 3 Display option 108 9 Decommissioning 110 9 1 Decommissioning a crane 110 10 Technical Data 112 10 1 Load plate table 112 10 2 Identification of the loader crane 113 10 ...

Страница 6: ...This page is intentionally left blank HIAB K HiPro 285 425 X4 ...

Страница 7: ... 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 equipment exactly Store the Technical Data and manuals from the I...

Страница 8: ...IAB 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 the Cleanliness Requirements for Hydraulic Systems This means that they fulfil the cleanliness class 20 18 14 measured by the ISO 4406 standard All hydraulic functions have been individually tested ...

Страница 9: ...ion are available for your crane DANGER Only persons with the requisite knowledge and experience with cranes may use the crane Never operate the crane when you are sick tired under the influence of medicines alcohol or other drugs Take the delivery instructions from your HIAB Service workshop or receive instruction from an experienced person from your own company Only then should you operate your ...

Страница 10: ...arings with a high pressure jet cleaner It could cause damage Never expose the electronic system to high electrical voltages This could damage the control system Never immerse the controller in water or other liquid 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 fro...

Страница 11: ...em The crane base column and the slewing system consist of the following components 1 Crane base with stabiliser beams 2 and three point bridge 3 4 Column fitted to the crane base 5 Rack and pinion slewing system 2 3 Stabiliser system Every HIAB crane is equiped with two stabiliser extensions and two stabiliser legs Auxiliary stabiliser systems may be needed for heavy cranes The stabiliser system ...

Страница 12: ...2 5 Accessories on the boom system 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 maximum permissible loading of the hook 1 2 3 Structure and parts of the HIAB crane 12 HIAB K HiPro 285 425 X4 ...

Страница 13: ...Separate lifting accessories option Separate lifting accessories help to make or use a slinging device eye hooks shackles eye bolts etc Structure and parts of the HIAB crane HIAB K HiPro 285 425 X4 13 ...

Страница 14: ...biliser control valve option 11 Return filter 2 Hydraulic pump 6 Hydraulic hoses and lines 12 Load holding valve 3 Oil cooler option 7 Slewing cylinders Motor reducers Pressure filter option 4 Main control valve Actuators 8 First boom cylinder 9 Second boom cylinder 10 Extension cylinder s Structure and parts of the HIAB crane 14 HIAB K HiPro 285 425 X4 ...

Страница 15: ...B K HiPro 285 425 The HIAB K HiPro 285 425 are compact fully hydraulically operated goods cranes Lifting capacity HIAB K HiPro 285 25 5 tonne metres 184 400 ft lbs HIAB K HiPro 425 34 tonne metres 245 900 ft lbs The crane is supplied in many versions from HIAB K HiPro 285 2 reach 13 6 metres 44 5 ft HIAB K HiPro 285 3 reach 16 1 metres 52 10 ft HIAB K HiPro 425 4 reach 19 1 metres 62 8 ft The cont...

Страница 16: ...rane 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 greater than at normal working temperatures To...

Страница 17: ...ulty 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 Twigs break off walking is difficult 9 20 8 24 4 Storm Causes superficial damage to buildings chimney pots roof tiles and TV antennae are blown off 10 24 5 28 4 Severe storm Uprooted trees considerable damage to buildings etc occurs infrequently on land 11 28 5 32 6 Very severe s...

Страница 18: ... such as 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 M...

Страница 19: ...working zone However take careful note the greater the operating 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 Neve...

Страница 20: ...he reach at which you are working and the optimum position of the boom The optimal position for your crane is on the load plate DANGER Never exceed the maximum weight on the load plate Load diagram The load diagrams are placed on the column and show the maximum loads your crane may lift in the entire working zone The load diagram drawing will also be found in the enclosed Technical Data The white ...

Страница 21: ...the OLP gives a warning and locks any crane movement that will increase the load moment This is known as an OLP situation If the second boom is raised then the following movements are locked 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...

Страница 22: ... 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 possible to the load Working below ground level If you have to load or unload below the level of t...

Страница 23: ...m 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 operator is obliged to follow the instructions and signals given by a qualified person qualified The country specific regulations for crane operator signals are to be used Signals in this manual give a number of standard signals that can be used Lift Rai...

Страница 24: ...y short movement Place the hands a very short distance apart with the palms facing each other The hands may be held either horizontally or vertically The next movement may be Lift lower move the lifting gear change the reach or turn Change the reach Signal with your hands Sideways movement outwards with both hands Thumbs outwards Sideways movement inwards with both hands Thumbs inwards Safety prec...

Страница 25: ...t shoulder height with the palms facing downwards Close the grapple Move both hands close together Lift the open grapple a little Extend both arms at shoulder height with the palms facing upwards Make vertical movements with both arms outstretched Safety precautions and warnings HIAB K HiPro 285 425 X4 25 ...

Страница 26: ... 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 operating them Do not lower the...

Страница 27: ...r 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 the boom tip and the load grapple rotator Separate lifting ac...

Страница 28: ...ctricity lines unless otherwise prescribed by national rules DANGER When you go into the control station high seat cabin platform remove all jewellery loose clothing or other hanging items from your body for example rings scarfs bracelets Jewellery loose clothes and other hanging items can be caught in some parts of the crane DANGER When you go into or out from the control station use only handles...

Страница 29: ...ins over 40000V power transmisson 3 5 2 Crane operation DANGER Your crane has a control system The control system will help you to work safely Nevertheless you remain responsible for safe use of the crane Therefore always work according to the operating instructions In an emergency immediately switch off all crane movements Push a stop button To avoid unexpected load movements and at every interru...

Страница 30: ...the person assisting you know these signals Pay attention to the safety of the person giving the signals Never move the vehicle if you have a freely suspended load on the crane Never walk or stand under a suspended load During operation never stand below the boom system or load Do not slew the crane nor lift the first boom nor lift the second boom into their ends positions at full speed This can d...

Страница 31: ...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 When loading the vehicle Take the load off the stabiliser l...

Страница 32: ...ng 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 For further instructions see vehicle s manual s Safety prec...

Страница 33: ... 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 of demountable cranes DANGER Ensure that there are no unauthorized persons in the immediate vicinity of the crane When mount dem...

Страница 34: ...er 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 Safety precautions and warnings 34 HIAB K HiPro 285 425 X4 ...

Страница 35: ... crane there are various sensors and indicators which send signals about the crane s load position and movements to a central microprocessor The microprocessor then decides how the crane can be operated and stops reduces prohibited movements speeds according to the following When prohibited movements speeds are approached a warning is given When prohibited movements speeds are reached On remote co...

Страница 36: ...system 1 3 6 4 5 7 8 2 10 9 11 1 Main control valve 5 Dump valve 2 option 9 XSDrive controller option 2 Stabiliser control valve 6 Selector valve option 10 CombiDrive controller option 3 User panel SPACE X4 UI 7 Pressure reducer filter 11 High seat option 4 Dump valve 1 8 Warning lamp option The HiPro system 36 HIAB K HiPro 285 425 X4 ...

Страница 37: ...l By default the symbol on the controller corresponds to the positive movement of the levers To operate the opposite movement of that symbol move the lever on the opposite direction Always operate the lever according to the function on the symbol sign Basic crane symbols and functions SYMBOLS FUNCTIONS SYMBOLS FUNCTIONS Slewing Second boom First boom Hydraulic extensions Accesories symbols and fun...

Страница 38: ...the main control valve levers The speed of a function corresponds to the extent of the lever movement regardless of the load and other functions as long as the oil flow is sufficient When the oil flow is insufficient one or more functions might reduce their speed When remote control is used the oil flow is allocated by means of PFD Standard functions and symbols The order of the functions is custo...

Страница 39: ...tem on and off Button 2 is stabiliser operation activation to enable operation of stabiliser extensions The driver must have full view when operating the stabiliser extensions outward Button 3 is used for OLP release if the crane is in an OLP situation and for disconnecting the automatic dump function Stop button 4 is pushed in an emergency Button 5 Once the controller is activated this button can...

Страница 40: ...lashing Critical error Manual extensions 4 Not active in this configuration Remote control 5 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 6 Blue light on Slew is in parking position Service 7 Green light on Service needed Red light on Error in the system Re...

Страница 41: ...ed LED test see Daily inspection 4 8 Dump valves Dump valve 1 1 Allows operation of the crane functions To prevent high pressure and thereby unnecessary heating of the oil there is an automatic dumping function When no lever movement has been made for 3 seconds the dump valve is opened and the oil is returned directly to the hydraulic tank As soon as the operator moves a lever the valve closes Dum...

Страница 42: ...ioner s 4 11 Warning lamps A warning lamp on each stabiliser leg is used to warn the surrounding about ongoing activity by amber light indication A warning lamp also gives information to the operator about the different statuses of the crane System ON the stabiliser leg lamps light up Remote control ON the stabiliser leg lamps blink 90 of maximum permitted load and OLP the stabiliser leg lamps fla...

Страница 43: ...r is visible on the controller In case of radio interference it is possible to change the channel by pushing button There is a maximum of 12 channels available WARNING When the controller is in use stop button released keep a distance of minimum 1 meter between the controller and the crane or truck because of possible electromagnetic interference Cable connection option The cable 2 is intended to ...

Страница 44: ... VSL OLP Vehicle has reached a stability limit Also all the 1st boom diodes will light red OLP Release 5 Red light on OLP Red light blinking OLP Release Low speed 6 Green light on Reduced speed For normal speed see section Buttons Cylinder pressure LEDs 7 Lower LEDs green light on 70 of maximum pressure Lower LEDs red light flashing 90 of maximum pressure Lower and upper LEDs red light 100 of maxi...

Страница 45: ... the same time to activate the manual extension 5 Speed selection At the start you have maximum operational speed Push the button to operate the crane with decreased speed Push it again for maximum speed 6 8 LSS V If the crane has LSS V button 6 activates this feature and button 8 deactivates it 7 Channel shift Push to change radio channel There are 12 channels in total 9 Stop button When you push...

Страница 46: ...e 4 LEDs flash at the same time for 5 times 4 LED 1 comes on Start menu 4 12 3 Menus The functions presented in each menu can be customized depending on crane configuration It can be changed by a Hiab Authorized Workshop The table below shows an example Menu 1 Slewing first boom second boom extension boom tools JIB hoist etc Menu 2 option If crane is equipped with extra remote controlled stabilise...

Страница 47: ...ols 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 The HiPro system HIAB K HiPro 285 425 X4 47 ...

Страница 48: ...be used to estimate remaining hours of use Battery charger 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 1 is lit continuously when the battery charger is ready for use Place the battery in the charger LED 2 flashes slowly during recharging and has a steady light w...

Страница 49: ...e cable connects to the vehicle at the connector 1 on the front of the decoder When the cable is connected to the controller 2 the centre display shows the symbol for cable operation 4 13 1 Displays The displays are of LCD type and will perform best in temperatures above 10 C At 0 C there is a delay in shifting symbols of approximately 1 sec At 20 C the delay will increase to approximately 8 sec A...

Страница 50: ...irmed by pressing the release button only then will the spanner go back to normal size 7 Main menu The text shows which main menu has been selected The number shows which sub menu is active The main menus are CRANE EXTRA and ON OFF 2 Micro Indicates that micro operation has been selected Micro operation changes the sensitivity of the levers as follows At full lever deflection μ50 gives 50 and μ20 ...

Страница 51: ... are not met 11 ADC Automatic Duty Control Indicates that the ADC function is active 6 Battery capacity The battery symbol shows remaining power in the battery When the symbol begins to flash there is capacity for just a few more minutes When this happens the horn on the crane will sound twice as an indication of low battery 12 13 SAF CTC option SAF function or CTC function is active CTC SAF Left ...

Страница 52: ...e specific crane Micro mode Push to choose micro mode Push again to choose normal mode 7 3 Menu CRANE Push to choose menu CRANE Stop button Push to deactivate the controller Release to activate 8 4 Menu EXTRA Push to choose menu EXTRA OLP release Push and hold to activate OLP release See section OLP release 9 5 Menu ON OFF Push to choose menu ON OFF Manual extensions Push simultaneously to activat...

Страница 53: ...t the stop button The centre display then shows a large locked padlock symbol Unlocking the controller 1 Push and hold button 4 and 5 while the stop button is pushed 2 Keep button 4 and 5 pushed while pulling out the stop button 3 Release button 4 and 5 The controller is ready to use 4 13 3 Menus standard functions and symbols The function of each lever may be the same or different in different me...

Страница 54: ...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 functions 1 6 without shifting CRANE menu CRANE menu button 3 When the operator pulls out the stop button on the controller it always starts in CRANE 1 menu The submenus in CRANE menu are configured in production but can be change...

Страница 55: ...ontroller CRANE MENU 1 2 3 Left side display Centre display Right side display Example of submenus for the 8 lever controller CRANE MENU 1 2 3 Left side display Centre display Right side display The HiPro system HIAB K HiPro 285 425 X4 55 ...

Страница 56: ...3 down up Auxiliary stabiliser leg 4 down up Crane stabiliser extension 5 out in Crane stabiliser extension 6 out in Auxiliary stabiliser extension 7 out in Auxiliary stabiliser extension 8 out in ON OFF menu button 5 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 ...

Страница 57: ...CTC mode crane tip out in 7 1st boom locked when operating CTC mode crane tip out in 8 Manually control the 1st boom up down in CTC mode 9 Manually control the 1st boom down up in CTC mode 10 4 13 4 Battery and battery charger Battery The voltage level of a fully charged battery is approximately 8 4V and it provides about 5 8 hours working time Note that the battery voltage remains between 7 6V an...

Страница 58: ...lights when the charger is activated 1 and 2 lights during charging 1 and 3 lights when the battery is fully charged Display B Shows the battery voltage 8 4 When the display blinks 0 0 there is error in the battery Change battery NOTE A charged battery is a concentrated energy source Never store a charged battery in a toolbox or similar where there is a risk of a short due to metal components Used...

Страница 59: ... 4 Pedal Slew clockwise counterclockwise For safety reasons it is necessary to sit down on the seat to operate the controls DANGER Take care not to put your foot on the pedals when taking place in the high seat Unintentional crane movements can occur Hydraulic stabiliser extensions and legs are controlled by an additional control valve fitted to the stabiliser beam Platform option DANGER Use the p...

Страница 60: ...g 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 Particular case 1 Working with extra load on the vehicle platform to benefit from VSL To avoid sudden movements of the vehicle and damages on the stabiliser system the...

Страница 61: ...d stall The maximum rpm may depend upon a governor on your PTO combination Start the control system The operating levers must be in neutral position before start up To start the control system push the On Off button on the user panel The LED above the button lights up The system will check itself for a few seconds The warning lamps on the stabiliser legs light up Starting crane operation HIAB K Hi...

Страница 62: ... on the stabiliser legs blinks Indications XSDrive The menu LEDs on the controller starts blinking When communication has been established the LEDs will give a steady light ready for use Indications CombiDrive Wait is shown on the centre display while radio contact is being established On the decoder LED 1 is lit LED 2 starts to blink When contact has been established CRANE 1 menu and signal stren...

Страница 63: ...e sure that the vehicle is stable while lifting a load and the maximum load is not exceeded Stability sector indication The operator must have a full view of the stabiliser system when operating it To confirm a full view of the stabiliser system button is pushed on the user panel on the side where the stabiliser system is going to be operated As soon as the button has been pushed the LED for the a...

Страница 64: ...maximum load P that the stabiliser leg can apply to the ground is kN Crane Model Stabiliser leg config Short Medium Long Extra long 265 285 200 200 395 425 335K 410K 435K 230 230 322 377 328 352 362 388 230 200 180 422 477 Medium Stab Exten 220 220 Long Stab Exten 240 240 Extra long Stab Exten 220 220 358 398 408 418 230 200 180 528 548 558 638 658 250 250 858 1058 370 370 370 370 HIAB Auxiliary s...

Страница 65: ...n on the user 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 stabiliser legs can be driven up and down regardless of the side If selector valve option If the crane has selector valve move lever 1 to stabiliser system position 5 ...

Страница 66: ...ing 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 WARNING 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 l...

Страница 67: ...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 section For this reason study the operating instructions for any add on equipment carefully Always ensure that the stabiliser extensions and legs are in working position and securely locked before operating the boom system out of...

Страница 68: ...h button 1 on the controller to change the menu into crane operation 1 NOTE As soon as you have selected remote control operation it is no longer possible to operate the main control valve levers If selector valve option If the crane has selector valve move lever 1 to crane position 1 Starting crane operation 68 HIAB K HiPro 285 425 X4 ...

Страница 69: ...ne to the working position 2 3 Extend the hydraulic extensions The crane is now ready for use 3 NOTE As soon as you have selected remote control operation it is impossible to operate the main control valve levers Starting crane operation HIAB K HiPro 285 425 X4 69 ...

Страница 70: ...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 set to 100 It is possible to choose betw...

Страница 71: ...tip instead of each crane function One lever is used for horizontal movement and one for vertical The crane will calculate and carry out the necessary operations to move the crane tip in and out or up and down CTC is operated in a separate menu on the controller How to operate the crane using CTC 1 Navigate to the menu for CTC NOTE The crane tip will not move until the 1st boom reaches its optimum...

Страница 72: ...lly 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 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 Dur...

Страница 73: ...he lifting capacity is increased during the complete lifting cycle 6 1 9 PFD Pump flow distribution When operating several functions simultaneously the pump flow may not be sufficient PFD will now take over reducing the speed of all operated functions Uncontrolled movements are thus avoided smooth simultaneous operation is achieved 6 1 10 Slewing sector option Within slewing sector lifting capacit...

Страница 74: ...ehicle platform is loaded the extra load acts as a counter weight This automatic function increases flexibility especially on worksites where it is not possible to utilize the full stabiliser extension reach WARNING In order to get the maximum benefit from the VSL system some of the wheels of the vehicle shall be lifted from the ground but Hiab strongly recommends that at least one wheel is braked...

Страница 75: ...d button 8 to deactivate Activate and deactivate LSS V By default with the controller CombiDrive 1 Push the ON OFF button 5 on the remote control CombiDrive with 6 levers Menu 2 ON OFF CombiDrive with 8 levers Menu 1 ON OFF 2 Move the levers according to the text in the display CombiDrive with 6 levers lever 4 activate and lever 5 deactivate CombiDrive with 8 levers lever 7 activate and lever 8 de...

Страница 76: ...is stopped in the direction towards the stabiliser leg where the OLP occurs The crane stops The warning lamps on the stabiliser legs will blink On the user interface the LED for the overloaded stabiliser leg will light red Move the levers to neutral and only operate permitted pressure reducing functions VSL OLP option VSL OLP occurs when there is a risk of instability of the vehicle Slewing is sto...

Страница 77: ...itted 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 f...

Страница 78: ...ws the symbol VSL The 100 symbol in the left display alternates with OLP for crane Move the levers to neutral and only operate permitted pressure reducing functions 6 4 To release OLP If all functions have been blocked due to OLP it is possible to temporarily release OLP and operate an appropriate crane function to correct the overload situation OLP release is active in 5 second intervals After ea...

Страница 79: ... OLP release on controller XSDrive Push and hold the button on the controller whilst operating load reducing functions On the user panel the cylinder pressure LEDs perform a running light The LED for padlock symbol will blink red OLP release on controller CombiDrive Push and hold the button 9 on the right hand side below the display handle The unlocked padlock will appear in the centre display On ...

Страница 80: ...ER During folding of the boom system always operate the crane manually from the position indicated in the figure With remote controlled cranes stay in a safety area while the boom system is moving Operate the boom system 1 Retract the extensions completely 1 2 Slew the crane until the crane is parallel to the vehicle 2 3 Lower the boom system against the vehicle 3 Do not extend the second boom cyl...

Страница 81: ...ry 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 vehicle Manually controlled crane Activate stabiliser system operation on the user panel by pressing button Remote controlled crane Manually controlled stabiliser system Press button on the user panel to deactivat...

Страница 82: ...om moving parts during operation Retract the stabiliser extensions The procedure of retracting the stabiliser extensions differs depending on the type of stabiliser extensions Repeat the instructions for the stabiliser extension on the other side of the vehicle For auxiliary stabiliser system option Repeat the process Hydraulically controlled stabiliser extensions Retract the stabiliser extensions...

Страница 83: ...ing emergency operation all crane security is disconnected Always go to contact a HIAB service workshop when the seal wire has been broken 1 Engage the pump 2 Break the security sealing on dump valve 1 1 on the main control valve 3 Use a screw driver or similar and push the knob on dump valve 1 1 4 Check that no unintended movements starts If you get unintended movements then release the knob and ...

Страница 84: ...the stabiliser extensions and stabiliser legs to transport position using the levers on the stabiliser control valve 7 5 TWI Transport warning interface option WARNING If you switch off the safety system when manual operated stabiliser extensions tiltable stabiliser legs are not locked in the transport position and or if the first boom angle exceeds a certain specified angle the indicator lamps fo...

Страница 85: ...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 load secure the boom and the lifting accessories to prevent any unintentional movement of the crane and the lifting accessories Ending crane operation HIAB K HiPro 285 425 X4 85 ...

Страница 86: ...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 vehicle Disconnect the power between the vehicle and the crane Contact the vehicle manufacturer After welding on the vehicle Connect the power between the vehicle and the crane Maint...

Страница 87: ...erating system 3 Disengage the PTO 4 Leaking coupling Tighten the coupling with a spanner If tightening does not help contact a HIAB service workshop 5 Small leak on a line or hose Determine if you can still park the crane If you can park the crane and go to a HIAB service workshop If you cannot contact a HIAB service workshop 6 In all other cases contact a HIAB service workshop 8 2 Warranty HIAB ...

Страница 88: ...ience of If the crane is not to be used for 1 month or longer Lubricate the crane thoroughly according to the lubrication schedule Park the crane in the transport position Filters Replace the filter cartridge after the first 50 hours operation then after every 1000 hours operation or at least once a year Cleaning Clean your crane and accessories regularly but Do not use aggressive cleaning agents ...

Страница 89: ...t the locking devices are properly locked Shafts shaft lockings bearings and bushings Check that the shafts shaft lockings bearings and bushings are undamaged and working properly Stop buttons Check that the Stop buttons are undamaged and working properly Levers Check that the levers operate smoothly Check that the levers return to neutral position Controller Do a check of the controller functiona...

Страница 90: ...two Spring Roll pins 8 and 9 should be in place and nearly flush with the outer edge of the hook nut 6 on both sides See the pictures Side 1 and Side 2 Do an inspection of the spring loaded safety Latch 2 The Latch must close the entire throat opening Do an inspection of the Clevis Link Shaft 3 Clevis Links Shaft nut 7 and Cotter Safety pin 4 are in place Do an inspection of the Plane bearing Wash...

Страница 91: ...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 workshop whe...

Страница 92: ...w fixings are not loose If loose contact a HIAB service workshop 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 slewing bearing upper column bearing is lubricated sufficiently Hydraulic system Check that the hydraulic pump attachment screws are tightened Check...

Страница 93: ... the latch assembly if it is damaged missing or malfunctioning Hook 8TN replace the hook for a new one if the Clevis Link or Split clevis retaining nuts are missing or damaged Hook 10TN replace the two spring roll pins and the plane bearing for a new ones at least once a year 8 4 Lubrication WARNING Follow the lubrication schedule exactly If you do not do so you can cause serious damage to the cra...

Страница 94: ...ation schedule AR Lubricate after every 16 hours of use Lubricate after every 50 hours of use Grease after every 50 hours of use A Internal pads B Internal guides Maintenance and Service 94 HIAB K HiPro 285 425 X4 ...

Страница 95: ... system Front upper slide pads Extend extensions with load in order to create enough clearance Lubricate Front lower slide pads Extend extensions without load and push slightly against the ground in order to create enough clearance Lubricate 8 4 4 Lubrication of the hooks Hooks with plane bearing If the hook cannot rotate easily without load 1 Lubricate the plane bearing surfaces 1 Use a heavy dut...

Страница 96: ... 8 3 Slew the crane to the end positions three times 4 Check the oil level If necessary top up again Measuring level glass if fitted Checking the oil level in slewing housing 1 Check if the oil level in the level glass 1 is between the maximum and minimum levels 2 If the oil level is below the minimum level Remove the plug 3 3 Top up through the filling hole 3 with transmission oil of type MIL L 2...

Страница 97: ...e crane 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 cont...

Страница 98: ...ness 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 performance of the oil complies with the above standards When changing from mineral oil to a non polluting synthetic oil or when changing to bio...

Страница 99: ...AB s requirements and must not be used After filling the tank 1 Operate each crane function to its end positions 2 Operate the crane to parking position 3 Check and top up the oil tank to max level on the tank gauge 4 Bleed the system 8 5 4 Bleeding air from the hydraulic system Bleed the air from the hydraulic system after changing the hydraulic oil after working on the hydraulic system if your c...

Страница 100: ... cartridges as recommended After the first 50 operating hours Then after every 1000 operating hours or once a year during regular service Main control valve V200 High pressure filter Located at the crane base connected to the pressure line from the pump Pressure reducer filter only remote controlled cranes Located in the outlet section of the main control valve It is usually located at the crane b...

Страница 101: ...il in a suitable container and clean or dispose of it in accordance with environmental regulations 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 segment especially sealing surfaces and thread for mechanical damage 8 Always replace t...

Страница 102: ...n the housing 3 Remove the filter housing using a 27 mm wrench 4 Remove 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 damage to the components 6 Clean the filter housing 7 Unpack the new filter cartridge Make sure that it is clean and scr...

Страница 103: ... of pressure 2 Clean the immediate surrounding area of the filter 3 Remove the cover 4 Remove the filter cartridge with attached filter housing by using the handle 5 Examine the surface of the filter cartridge for dirt residue and larger particles these can indicate damage to the components 6 Examine the filter housing for any possible mechanical damage 7 Replace the filter cartridge with a new on...

Страница 104: ... 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 Remote control user panel MUX box Truck warning interface Work lights 15 A Located inside the relay box 1 Fuse for all components connec...

Страница 105: ...rectify Follow the instructions exactly All other faults must be corrected by personnel in a HIAB service workshop Fault Probable cause Action Electronic system will not start Parking brake on the truck is not engaged Engage parking brake on the truck The hydraulic pump makes a noise Warning Stop using the crane immediately Oil tank filler breather is clogged Clear the blockage or replace the enti...

Страница 106: ...d or add an extra support plate between the cylinder and ground Slewing support cylinders do not turn Three way valve failure Go to a HIAB service workshop Irregular slewing movements and unusual noises in cranes with rack and pinion slewing system Insufficient oil in the hydraulic system Top up the oil tank Insufficient oil in the slewing housing Top up the oil in the slewing housing to the requi...

Страница 107: ...e workshop Cane performance when operating 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 workshop Cylinder internal leakage Go to a HIAB service workshop Boom extension cylinders do...

Страница 108: ...ggle button or the OK button In the bottom left of the screen the name of the item currently highlighted is shown Buttons 1 Push to go back to main menu 2 Push to go back one step 3 Push to toggle between menu items 4 Push 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 ...

Страница 109: ...t percentage of working pressure and red indicates the lowest percentage Function indication If function LSS V is activated the screen turns blue and a symbol of a hook is shown This to notify the operator of the occurrence When the screen goes back to normal the symbol of the hook is shown in the top right of the screen When deactivating LSS V the screen turns blue again and the hook symbol is sh...

Страница 110: ...aw 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 structures manufactured from steel or cast iron hydraulic cylinders and lines dr...

Страница 111: ...ses from the joints and journal bearings other waste containing oils and greases hydraulic 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 designated by local authorities Responsible col...

Страница 112: ...en the crane has VSL option the Installer should fill in the valid meters m or feet ft and kilos kg or pounds lb in this table following instructions given in the Installation instructions m ft kg lbs Technical Data 112 HIAB K HiPro 285 425 X4 ...

Страница 113: ... Load Stabilising System Horizontal Load Stabilising System Horizontal 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 Pu...

Страница 114: ... 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 reproduce this checklist is granted however please n...

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