Hiab 335k Operation Maintenance

Operator's Manual GBHIAB 335K Pro-HiPro CD This manual applies to crane 3350686 and from serial number: 3350690 2012-06 Congratulations with your new crane! You are now the owner of a quality product from Cargotec, built to the highest standards of safety and quality. The aim of this manual is to help you handle your crane safely and with full satisfaction. Please read the complete manual. It provides detailed information about the crane, safety system and the practical management and maintenance of the crane. We advise you to read it carefully and familiarize yourself with your crane before you start to use it. 2 Operator's Manual GB Table of Contents 1. 2. 3. Knowledge required ............................................................................... 6 1.1 This Operator's Manual is intended for operators of this HIAB crane. .... 6 1.2 Indications in the Operator’s Manual ................................................ 7 Structure and parts of the HIAB crane ..................................................... 10 2.1 Main groups ............................................................................... 10 2.2 Crane base with column and slewing system .................................... 10 2.3 Boom system .............................................................................. 10 2.4 Stabiliser system .......................................................................... 12 2.5 Operating system - hydraulic components ........................................ 13 2.6 LHV Load holding valves ............................................................. 13 2.7 Description of Hiab 335K Pro/HiPro-CD ......................................... 14 Safety precautions and warnings............................................................. 15 3.1 3.2 4. Operating conditions .................................................................... 15 Definition of a HIAB loader crane .................................................. 3.2.1 Noise declaration ................................................................. 3.2.2 Warning signs ..................................................................... 3.2.3 Maximum load .................................................................... 3.2.4 Maximum load moment ........................................................ 16 17 18 18 21 3.3 Signals when using a crane............................................................ 24 3.4 Wind speeds ............................................................................... 28 3.5 Use of the crane .......................................................................... 29 3.6 Use of lifting equipment ............................................................... 36 3.7 Use of dismountable cranes ........................................................... 36 The Safety system................................................................................ 38 4.1 Safety System SPACE 3000/5000 and Remote Control ...................... 38 4.2 How the safety system works......................................................... 38 4.3 Components of SPACE Safety System ............................................ 40 4.4 Operating components .................................................................. 42 4.5 Main control valve ....................................................................... 42 4.6 Stabiliser control valve ................................................................. 44 4.7 Extra stabiliser leg [option] ........................................................... 45 4.8 Selector valve [option].................................................................. 45 Operator's Manual GB 3 ..........................4 Lubrication ............................................................3 Follow the maintenance instructions! ................................ 66 5............................................................ 81 7........................................................................................1 Daily inspection ..............................................................................................2 Warranty .. 46 4... 47 4.........1 Indicator lights on user panel SPACE 3000 ............................................... 66 5............. 62 4...............11.... 48 4......................... 4... 91 Operator's Manual GB 86 87 88 90 ......................6 Emergency operation Valve-V91 .......4..............................9 Cranes with high seat [option] ........ 8...............................1 7.15 Battery charger CD2 ................................. 8.... 90 8....... 84 8........................... 84 8.......... 80 7.................................................... 8...............................................................................4..............................................................................1 Indicator lights on user panel SPACE 5000 ...............................................1 Service ..... 74 6..............................3........ 70 5............................................... 79 7................................Table of Contents 5.... 4 OLP (Overload protection) ............................ 72 During operation .................................16 Functions ........................................................................3......... 63 Starting crane operation .....4 Placing the stabiliser extensions and legs in transport position .................................1 Operate the crane to parking position ............................ 8..3..................................14 Main menus CombiDrive2 .........12 User panel SPACE 5000 .... 52 4.........2 Monthly inspection and maintenance .............................................10 OPS Operator Protection System [option] ............ 8........................................................ 6....2 Extend stabiliser extensions and set stabiliser legs .................................. 55 4..............1 Lubrication schedule ........... 91 8.................................. 82 Maintenance and Service ........ 85 8.............................................. 74 Ending crane operation ............................... 79 7...11 User panel SPACE 3000 ........13 CombiDrive2 .........................................................1 Starting operations .................5 Switching off the safety system .......................12...............3 Annual maintenance ................................ 47 4...7 TWI Transport warning interface [option] ...........2 Lubrication of slide pads in boom system ....................3 Operate the crane out of parked position .................. 81 7................ 50 4....................................... 49 4.. .............2 Faults in the HiPro crane .............. 8..1 Slewing housing: checking the oil level/oil change .........................2 Replacing the return oil filter ................................................... 8..... 8...............5................5 Checking the oil tank level ........4.......6.........5..................................3 9...6 Troubleshooting .....................................6 Changing the hydraulic oil .............. 8...................................................................................................... 98 93 93 94 94 95 95 95 97 Decommissioning................. 8......................4 High pressure filter [option] ...3 Replacing the cartridge in the pressure reduction filter ............................... 8.....5.............................................. Lubrication of the upper column bearing and three-point bridge......................................................7 Bleeding air from the hydraulic system................................................................................ 104 Operator's Manual GB 5 .............................................. 98 8......5 Hydraulics ...... 92 Decommissioning a crane .................1 Main fuses.................1 10.. 8...5..... 8. 102 9........................6........1 Documentation ............................... 102 Technical Data ..........5..............5.......5.. 98 8..................... 104 10....................................... 8.........Table of Contents 8.. it could lead to fatal accidents or serious damage. • Follow the directions for use.Knowledge required 1 1. Therefore you should: • Study the entire Operator’s Manual carefully. operation and maintenance of the crane and add on equipment exactly. • Store the Operator’s Manual for your type of crane. 6 Operator's Manual GB .1 This Operator's Manual is intended for operators of this HIAB crane. • Use the crane only after having done so. • Study the operating manuals for other add-on equipment. together with this Operator's manual. This manual describes: • Operation • Safety precautions and warnings • The crane safety system • Maintenance and troubleshooting Enclosed to this manual the Installer will provide: • Technical Data for your crane • Technical Data and manuals for add on equipment if fitted Study these instructions carefully DANGER If you do not study the complete Operator’s Manual for your crane carefully. if fitted. the Technical Data and manuals from the Installer. operating instructions and maintenance instructions without prior notice.... . equipment... or danger of serious damage to the crane or other objects. Do this 2.2 NOTE The manual is written in English and translated to the local language by the manufacturer. Operator's Manual GB 7 .. Follow the instructions carefully. CAUTION Hazard for the crane or crane components. Follow the instructions carefully. 5. Follow the instructions carefully! WARNING Danger of injury to yourself or to bystanders.. . Important: If actions are numbered 1.Knowledge required 1... 4... The manufacturer reserves the right to change specifications.. . Do that 3. 1.2 Indications in the Operator’s Manual What must you do and not do? The following indications are used in the Operator’s Manual: DANGER Danger to life for yourself or to bystanders.. or receive instruction from an experienced person from your own company. Only then should you operate your crane.2 you should carry them out in numerical order! NOTE Extra information that can prevent problems. tired.Knowledge required 1. under the influence of medicines. obligatory safety-helmet). alcohol or other drugs. DANGER Only persons with the requisite knowledge and experience with cranes may use the crane. • Ensure that you comply with the statutory requirements of the country in which you use the crane (for example. • Take the delivery instructions from your HIAB Service workshop. 8 Operator's Manual GB 1 . Symbol for reference to a component in an illustration. ① Refers to a component in an illustration. but are an option. certificate. [option]: Indication for parts that are not-standard for the crane. TIP Tip to make the work easier to carry out. Never operate the crane when you are sick. rotator.2 DANGER • Carry out yourself only the service and maintenance work you have the requisite knowledge and experience of. This will make the controller unusable. signs or bearings with a highpressure jet cleaner. • Take particular note when placing the crane in to or out of transport position. • Never expose the electronic system to high electrical voltages. before you use the crane. • Follow the instructions exactly! • All other work to rectify faults must be performed by personnel in a HIAB service workshop! WARNING • Never clean the electronic system. • You should therefore study the Operating Manual for the add-on equipment carefully. • Never immerse the controller in water or other liquid. etc. • Ensure that every defect is rectified immediately. Operator's Manual GB 9 . This could damage the safety system. It could cause damage. • All other maintenance work may only be carried out by a HIAB service workshop.Knowledge required 1. according to the instructions.): • The operation of the crane with add-on lifting equipment can differ from the operation as described in this manual. If your crane is equipped with add-on lifting equipment (hoist. plastic components. • Slewing system 2.3 Boom system The boom system consists of the following components: • 1st boom ① • 2nd boom ② • Hydraulic extensions ③ The extensions are operated by hydraulic cylinders placed inside the extensions.Structure and parts of the HIAB crane 2 2. 10 Operator's Manual GB 1 3 2 . column and the slewing system consist of the following components: • Crane base with stabiliser beam.2 Crane base with column and slewing system Boom system Stabiliser system Operating system Crane base with column and slewing system The crane base.1 Main groups The HIAB crane consists of the following main groups: • • • • 2. • Column this fitted to the crane base and turns in an upper and a lower bearing. column bearings and three-point bridge. shackles. eye-bolts etc. Separate lifting accessories [option] Separate lifting accessories. help to make or use a slinging device: eye-hooks. pallet fork. Operator's Manual GB 11 . grapple.3 • Add-on lifting accessories [option] Add-on lifting accessories are placed between the boom tip and the load (e.Structure and parts of the HIAB crane 2.g. rotator). • Stabiliser locking device ④.4 Structure and parts of the HIAB crane Stabiliser system Every HIAB crane is equiped with two stabiliser extensions and two stabiliser legs.4 2. Place the stabiliser legs on firm levelled ground to support the crane. The stabiliser extensions are hydraulically slid out from the stabiliser beam. The support plates are used under the stabiliser legs for additional support. 12 Operator's Manual GB . • Stabiliser extensions ②. • Stabiliser beam ①. • Support plates ⑤. Auxiliary stabiliser systems may be needed for heavy cranes.2. The stabiliser beam is a part of the crane base. • Stabiliser legs ③. hose or a coupling. also in the unlikely event of a burst hose. If there is a leak or a component fractures. and you operate a particular crane function.5 2.6 LHV Load holding valves All cylinders are equipped with load-holding valves as a safety device. such as a pipe. After a crane movement they hold the crane in position. Operator's Manual GB 13 .5 Operating system . To operate a hydraulic cylinder equiped with a load holding valve.Structure and parts of the HIAB crane 2. even when the hydraulic system is switched off. the load-holding valves will stop the booms from collapsing down.hydraulic components The operating system consists of the following hydraulic components: • • • • • • • oil tank hydraulic pump oil cooler [option on some cranes] main control valve stabiliser control valve [option on some cranes] hydraulic hoses and lines actuators: first boom cylinder second boom cylinder extension cylinder/s slewing cylinders / motor reducers return filter pressure filter [option] • • 2. an opening pressure is required. NOTE The exact technical information for your crane is shown in the Technical Data.7 Description of Hiab 335K Pro/HiPro-CD The HIAB 335K are compact. CombiDrive2 and the SPACE 5000 safety system are standard equipment on the HIAB 335K HiPro CD.6 to 28.3 metres (56' 9" ft) The main control valve V91 and the SPACE 3000 safety system are standard equipment on the HIAB 335K Pro. fully hydraulically operated goods cranes.9 tonne metres (192 470' 6" ft-lbs to 208 672' 6" ft-lbs) The cranes are supplied in a version: • HIAB 335K-4 reach: 17. The crane type and the manufacturer are marked on the serial number plate. Lifting capacity: • HIAB 335K = 26. The main control valve V91.Structure and parts of the HIAB crane 2.7 2. 14 Operator's Manual GB . • With a mean wind velocity less than 13.3 m/sec (approx. or in spaces with sufficient ventilation. • Variable pump: Operator's Manual GB 15 . Never use the crane during a thunderstorm.1 3 Operating conditions You may only use the crane under the following conditions: • In the open air. DANGER • If you use the crane in a confined space you could suffocate from the exhaust gases from the vehicle. To minimise wear.3 m/sec (approx. • Allow the system to idle for a few minutes. 29.Safety precautions and warnings 3. WARNING • At temperatures below 0 °C (32 °F): Do not touch the operating levers during the first few minutes. the wear on the hydraulic system is greater than at normal working temperatures. 29. • Fixed pump: Operate the stabiliser leg up for one minute in order to warm up the oil. • When starting in cold weather.7 mph) the crane will behave unpredictably. the crane should be started as follows: • Engage the power take-off at low rpm. When the mean wind velocity exceeds 13. as the steel's properties deteriorate below this temperature. • Never use the crane in a high wind or storm. • Never use the crane at temperatures below -40° C (-40 °F).7 mph). See the wind speed table. beams. The cranes are normally mounted on a vehicle but they can also be mounted on a fixed base plate. e. notice boards. plastic…) • Installation of informative posts. from another vehicle or from the ground • Hoisting. street lights… 16 Operator's Manual GB . bricks. taking the material from the vehicle on which the crane is mounted.) in building constructions • Lifting construction material (wall boards. traffic lights. paper.g. windows..Safety precautions and warnings 3. 3. in order to warm up the oil. vehicles…) • Collection of waste and recycling material (glass. boats. blocks…) on a pallet fork to a building.2 Definition of a HIAB loader crane Usage of the crane The HIAB loader crane is used to lift and move loads in the working area permitted by the load plate and the load diagram.. concrete plates and any other material and equipment used in building construction • With a bucket. moving filling material at a construction site • Handling large loads (containers. cardboard. road signs. machinery. Loader cranes are designed for loading and unloading the vehicle.2 Operate stabiliser legs up and down for one minute. as well as for other duties as specified: Permitted duties: • Loading and unloading cargo from/to a vehicle • Lifting of loads from the ground/vehicle to a higher place • Installation work (beams. concrete plates. The crane can be equipped with a number of accessories. 1 Forbidden duties: • Crane mounted onboard ships or floating structures.Safety precautions and warnings 3.2. 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…) 3.2.1 Noise declaration The following values for emitted noise may be taken as general and conservative values for ordinary installations of loader cranes on normal diesel engine powered trucks. work with submerge boom system or accessories. in strong currents such as rivers • Loading cargo that is partially loaded or fastened by other means. Declared dualnumber noise emission values in accordance with ISO 4871: • Emitted A-weighted sound power level for basic loader cranes in accordance with ISO 3744: LwA = 103 dB (Uncertainty: KwA = 2 dB) • Emitted A-weighted sound power level for loader cranes with hoist in accordance with ISO 3744: LwA = 107 dB (Uncertainty: KwA = 2 dB) • A-weighted sound pressure level at loader crane control stations in accordance with ISO 11201: LpA = 95 dB (Uncertainty: KpA = 4 dB) Operator's Manual GB 17 . except for cranes prepared for that purpose • Handle loads. only permitted in cases authorized by HIAB • Continuous use as a production crane in assembly lines. foundries…. Malpica. 86 ZARAGOZA . 3. YEAR HIAB CRANES S. The load plate and the load diagram on your crane show the maximum loads you may lift in the operating reach of your crane. in which case a post installation noise measurement in accordance with clause 6.3 of EN 12999:2011 may be used to prove this. L.2. This lifting capacity is also known as the load moment.SPAIN 3.3. The lifting capacity of your crane determines the maximum load your crane may lift within its working zone.2 Warning signs XS XS LOADER CRANE TYPE SERIAL NO MANUF. E. The lifting capacity is: the payload at hook multiplied by the outreach in metres that the crane can operate at different positions.2. the greater the operating radius of the crane. 18 Operator's Manual GB . expressed in kNm or tm. the lower the lifting capacity will be because of the weight of the boom system itself. P.2. However take careful note.3 Maximum load Lifting capacity Your crane has a certain lifting capacity.2 Safety precautions and warnings Particular installations can be quieter. 3 DANGER • Overloading could result in damage to the crane or in the worst case. In chapter Technical Data in this manual you will find these values for your crane. personal injury or death. • Never use the crane with the OLP system switched off. with lifting accessories the load you can lift is less heavy Load plate You will find the load plate next to the control valve.Safety precautions and warnings 3. • Never increase a hanging load. since that may cause a load holding valve to open and/or the vehicle to turn over. Optimum position The weight that your crane can lift will be determined by: • Stabilty test of your crane on vehicle [if VSL as option] • Stabiliser extensions positioned and legs pressed to ground. • The optimal position for your crane is on the load plate. with the 1st boom in the optimum position. Thus.2. ! NOTE The extra weight of the lifting accessories has to be added to the load. Operator's Manual GB 19 . • The reach at which you are working and the optimum position of the boom. On the plate is the maximum weight that you may lift at a given reach. DANGER Never exceed the maximum weight on the load plate. 3 Safety precautions and warnings Load diagram The load diagrams are placed on the column and show the maximum loads your crane may lift in the entire working zone. WARNING Never operate the hydraulic extensions against a solid objet when the first boom is completely lifted. WARNING Care must be taken when handling loads in the high lifting area. The load curves show the maximum load that may be lifted at a given reach and height. The lifting capacity for some cranes is limited in the high lifting area. so the load/tool does not come into contact with the boom system.3. The white area is the working zone of the crane. the possible working zone is to the left of the load curve. Do not try to push or compress loads when the first boom is fully lifted. For a given maximum load. 20 Operator's Manual GB .2. as this could cause damage to the first boom cylinder. The load diagram drawing will also be found in the enclosed Technical Data. you could cause a fatal accident or serious damage.Safety precautions and warnings 3. then the following movements are locked: • first boom down/up • second boom down • extension boom out If the second boom is down. Operator's Manual GB 21 .4 Maximum load moment If your crane has reached the maximum load moment (lifting capacity). the OLP gives a warning and locks any crane movement that will increase the load moment.4 3. If you cannot see the load properly.2. This is known as an OLP situation.2. If the second boom is raised. then the following movements are locked: • • • • first boom up second boom up extension boom out first boom down (certain crane types and cases) Lifting the load You obtain the best from your crane in this way: Ensure that you always have the work in clear view. The maximum working load (usually known as the working load limit (WLL) in standards) of a multilegged sling for general purposes is calculated by multiplying the WLL of a single leg by a mode factor. The angle between the legs of the sling must not exceed 120°.5 If the angle between the legs of the sling exceeds 90°.4 Sling length Always attach the load using the shortest possible sling.4 2. The crane then has the greatest lifting capacity. Place the vehicle as close as possible to the load.2. Working close to the load Always try to lift the load with the extension boom retracted. in accordance with the table. however not completely. Max angle to the vertical of any sling leg (degrees) Mode factor two legged sling Mode factor three and four legged sling 0-45 1. 22 Operator's Manual GB >1200 . the slings should not be hung directly on the hook.Safety precautions and warnings 3.1 45-60 1.0 1. but rather be slung from a ring that is hung on the hook. Only use the first boom . Heavy loads Lift heavy loads with the second boom in the optimum position in relation to the first boom.2. Heavy loads cannot be handled with the boom straight. angle down the second boom somewhat. For this. Loads at the extreme limit of the working zone Also in this case. TIP Make smooth crane movements: operate the crane with various functions simultaneously. Operator's Manual GB 23 .4 Working below ground level If you have to load or unload below the level of the ground: keep the first boom angle to about 10 to 30° above the horizontal plane. DANGER Never exceed the maximum permissible loading of the hook. see the load plate on your crane. so there is an angle in relation to the first boom.Safety precautions and warnings 3. In this way you will also prevent the hydraulic system heating up quickly. Set the second boom. Lower Arm pointing downwards and index finger down.Safety precautions and warnings 3. 24 Operator's Manual GB . • 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. Circular motion with hand.3 3. Circular motion with hand.3 Signals when using a crane 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. Lift Raised arm and index finger raised. • Sideways movement outwards with both hands. Very short movement Place the hands a very short distance apart. The hands may be held either horizontally or vertically. lower. Raise the hands and the arms to an oblique angle. with the palm clearly visible. The next movement may be: Lift. • Sideways movement inwards with both hands. Keep the hand still. or turn. Thumbs inwards. Raise the open hand. change the reach. with the palms facing each other. Operator's Manual GB 25 .3 Stop all crane movements Also: Hold the load in position. move the lifting gear.Safety precautions and warnings 3. Emergency stop for all movements by the crane. and arm at shoulder height. Thumbs outwards. Change the reach Signal with your hands. 3 Safety precautions and warnings Turn in the direction indicated Indicate the direction with the hands. with the palms facing downwards. Open the grapple Extend the arms at shoulder height. Close the grapple Move both hands close together. 26 Operator's Manual GB .3. Make vertical movements with both arms outstretched.Safety precautions and warnings 3. Operator's Manual GB 27 .3 Lift the open grapple a little Extend both arms at shoulder height. with the palms facing upwards. with the fist clenched. Keep the grapple in position briefly Raise the hand drooping slightly. 20.1 Severe wind Entire trees move.4 Wind speeds Wind speed averaged over 10 minutes at a height of 10 m Above flat ground Wind Force m/s 0 0.8 . walking is difficult. Dust and paper begin to move over the ground.4 3.5 1.24.0 .6 Hurricane Operator's Manual GB . leaves begin to rustle and weather vanes can start to move.3.3 3 4 3.0. Fairly strong wind Small leaved branches make swaying movements.4 Causes superficial damage to buildings (chimney pots.1.5 . 6 10. 8 17. Severe storm 10 24. (occurs infrequently on land).2 1 2 0. 12 > 32. Storm 9 20. the wind begins to be noticeable on the face.5 . and TV antennae are blown off). roof-tiles.0 . small branches begin to move.7.10.7 Stormy wind Twigs break off.8 .13.8 7 13. crested waves form on lakes and canals.32.4 Uprooted trees.4 .28. Strong wind Large branches move.17.3 .5 . considerable damage to buildings etc.6 .7 28 Characteristics Wind type Calm Calm.9 5 8. umbrellas can only be held with difficulty. smoke rises vertically or nearly vertically Slight breeze Wind direction recognisable from smoke plumes. 11 28. Moderate wind Leaves and twigs in continuous movement.4 5. the wind causes difficulty when you walk into it. you can hear the wind whistling in telephone wires.6 Very severe storm Causes extensive damage (occurs very infre quently on land).9 .Safety precautions and warnings 3.2 .5. Safety precautions and warnings 3. use support plates under the stabiliser legs for additional support. while the crane has a load! • Never unfold the crane from the position shown. • Slide the stabiliser extension. Operator's Manual GB 29 . Check that the support plate does not bend under load. on both sides of the vehicle. Use support plates that are large and firm enough for your crane.5 3. • Do not stand in front of the hydraulically operated stabiliser legs when you are operating them! • Where the ground is not firm enough. • Do not lower the stabiliser legs on the edge of an embankment. if the crane is equiped with only two stabiliser legs! If you raise the vehicle with the stabiliser legs.5 Use of the crane Starting crane operation DANGER • Ensure you can see the stabiliser legs and stabiliser extensions when you are operating them. Lower the stabiliser legs only on to a flat surface. Check that the support plate as. WARNING • Use low force when placing the stabiliser legs on the ground. this may damage the stabiliser legs. slope etc. it comes under load. soft shoulder. • Do not raise the vehicle with the stabiliser legs. out completely if possible. Then lower the stabiliser legs for support. • Never operate the stabiliser legs. is not pushed into the ground. g.5 m 4m >40000 V 2.0 m 6m Voltages are found: up to 500 V: to buildings 500-40000 V: trams. Minimum distance between crane and over head electricity lines Voltage (V) Minimum distance to an insulated conductor Minimum distance to an uninsulated conductor <500 V 0. unless otherwise prescribed by national rules. with cones.5 Preparations for use DANGER Ensure that there are no unauthorised persons within the operating range of your crane! TIP Mark out the working range. trains over 40000V: power transmisson 30 Operator's Manual GB .5 m 2m 500-40000 V 1.Safety precautions and warnings 3. Put on your vehicle's warning lights. DANGER • If a part of the crane comes in contact with an electricity line. e. you will be electrocuted! • Maintain the following minimum distances between the crane and overhead electricity lines. chains. for example because of frost: Place chocks under the wheels. Crane operation DANGER Your crane has a safety system. check that the ground is not undermined. cellars. since the vehicle could start to slide. always work according to the operating instructions! Operator's Manual GB 31 . • Also. chackles etc). • Activate the vehicle parking brake! Otherwise. Look out for sewers. the vehicle can start to move during lifting. you remain responsible for safe use of the crane! Therefore. The safety system will help you to work safely. JIB) or placed between the boom tip and the load (grapple. Separate lifting accessories are connected to the standard load hook (slings.Safety precautions and warnings 3. rotator). • 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. The stabiliser legs must not be able to sink in! • On a slippery surface. excavations etc. • Check that the ground is sufficiently firm. Nevertheless. Use chocks under the wheels on a gentle slope.5 DANGER • Wear a safety helmet (compulsory in some countries!). • Check that the ground is sufficiently flat. • Never use the stabiliser legs as a parking brake. have someone else give you signals. See the list of signals. • Press a stop button DANGER • Keep checking that there are no unauthorised 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. never stand below the boom system or load! • Do not slew the crane. • Pay attention to the safety of the person giving the signals! • Never move the vehicle. This can damage the crane.5 In an emergency immediately switch off all crane movements! • Press a stop button. nor lift the second boom into their ends positions at full speed.Safety precautions and warnings 3. Make certain that you and the person assisting you know these signals. nor lift the first boom. To avoid unexpected load movements and at every interruption in crane operation. if you have a freely-suspended load on the crane! • Never walk or stand under a suspended load! During operation. 32 Operator's Manual GB . Safety precautions and warnings 3. • If a cylinder is at its end position. Do not tow the load over the ground. with the extension boom. • If you are working with loads in restricted spaces (for example. when loading and unloading the crane. The boom system will bend somewhat. free the operating lever.5 WARNING • Never push a load along the ground. This could damage the slewing bearings and the connection between the crane column and the crane base. Be careful if. the OLP gives an early warning! • When loading the vehicle: Take the load off the stabiliser legs by withdrawing them slightly. • If the boom system is in a high position (first boom above 70°). in particular. This can cause damage to the boom system. This can damage the boom system. Operator's Manual GB 33 . The crane could go into an uncontrolled movement. This will lead to expensive repairs. • Never use the extension boom as a jack. • Always lift the load from the ground before you start to slew. CAUTION • Operate the crane using smooth and gentle lever movements. or the vehicle's load space. do not allow the boom to lower at full speed. windows): Check that the boom system can move up and down freely. Otherwise overheating can occur. The stabiliser legs must remain in light contact with the ground. The PTO or power supply must be disengaged. The crane has to stay within the width of the truck. tunnels etc. Make sure the stowed crane can not hit bridges.Safety precautions and warnings 3. For further instructions see vehicle's manual(s).5 Driving with the crane DANGER • Never drive the vehicle if there is a load suspended from the crane. • Before you move the vehicle: Check that there is no pump flow to the main control valve. • Pay attention to overhead power lines! Make sure that no part of the crane ever comes in contact with overhead power lines. The operating system must be switched off! • Pay attention to the width and height of the crane in the transport position. 34 Operator's Manual GB . • Check that the locking mechanisms are properly locked. • Only after doing the above. this will cause serious damage to the PTO/gearbox combination. • Withdraw the stabiliser legs and stabiliser extensions. should you drive the vehicle away.Safety precautions and warnings 3. • Lock tiltable stabiliser legs and manual operated stabiliser extensions in transport position. or over the load. always place the crane in the transport position! • When you have to park the boom on the load space. • If you drive with the PTO or power supply engaged. Operator's Manual GB 35 . secure the boom and the lifting accessories to prevent any movement of the crane and the lifting accessories. • Switch off the operating system.5 Ending crane operation DANGER Always end crane operation as follows: • After use. • Disengage the PTO or power supply after work. 2. WARNING • Clean the couplings. • Never attempt to install add-on lifting accessories yourself! • Add-on lifting accessories may only be installed by an authorised HIAB service workshop. follow the instructions supplied with the equipment! • Watch out for hazards! • Never try to adjust lifting accessories when you are working on the crane! After the lifting accessories have been fitted: 1. Contact a HIAB service workshop. when connecting and disconnecting lifting accessories.6 3. Only after this should you use your crane. • When using lifting accessories. Check that the lifting accessories are securely fixed. • Take care that your fingers are not trapped 3.Safety precautions and warnings 3. When mount/dismount the crane to the vehicle people can suffer fatal crushing injuries! • After setting up: Check that the crane is properly locked! 36 Operator's Manual GB .6 Use of lifting equipment DANGER • Only use lifting accessories that are suitable for your crane.7 Use of dismountable cranes DANGER • Ensure that there are no unauthorized persons in the immediate vicinity of the crane. Dirt can damage the hydraulic system. Safety precautions and warnings 3.7 WARNING Take care when mounting/dismounting the crane on/off the vehicle. Roughly handling can seriously damage the crane or the vehicle. Operator's Manual GB 37 . Certain functions are standard. • Makes troubleshooting easier. 4. SPACE 3000 is used on cranes with manual control. others are options. SPACE 5000 is used on cranes with control valve type V91 and remote control CombiDrive2. The safety system: • Monitors the crane's operation and prevents unsafe actions.The Safety system 4 4.2 How the safety system works The safety system works as follows: 38 Operator's Manual GB . This feature can be cancelled. Contact your HIAB Service workshop. • Makes operation easier. If you do not use the system for 30 minutes. it will switch itself off.1 Safety System SPACE 3000/5000 and Remote Control SPACE 3000 and 5000 are different versions of a crane safety system. in order to prevent draining the truck battery. • Increases the precision with which you can work. Crane version Control Valve Safety system Pro V91 SPACE 3000 HiPro V91 SPACE 5000 NOTE The safety system provides a large number of functions. The control valve is type V91. With the remote control CombiDrive2 you can control the crane remotely. Fault monitoring When there is a fault in the safety system it will give an immediate warning. Repairs may only be made by a HIAB service workshop! Operator's Manual GB 39 .2 On the crane there are various sensors and indicators which send signals about the crane’s load. 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. On manually operated cranes. use of the crane is blocked completely. When the fault is serious. a warning is given. position and movements to a central microprocessor. because when a spool is moved too much. • When prohibited movements/speeds are reached: On remote controlled cranes prohibited movements are stopped. all movements are stopped. DANGER Never try to repair the safety system yourself.The Safety system 4. power to the dump valve is cut. Depending upon the fault the crane speed and/or the load capacity will be reduced. all movements are stopped. Dump valve 1 ④ • To prevent high pressure and thereby unnecessary heating of the oil there is an automatic dumping function.The Safety system 4. Dump valve 2 • Allows operation of the stabiliser extensions and legs only when this valve is activated. Filter ③ • Pressure reduction filter.3 4. There is also an emergency stop button on the user interface. it is impossible to operate the main control valve levers. Here is where the operator turns on and off the system and activating stabiliser legs and OLP release.3 Components of SPACE Safety System Main control valve ① • The crane can be operated from the main control valve. 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. The dump valve 2 will be placed between the main control valve and the stabiliser control valve. Decoder ⑤ 40 Operator's Manual GB ➈ ➂ ➃ ➁ ➆ ➀ ➈ ➄ ➅ ➇ . The dump valve 2 must be activated from the SPACE interface before the stabiliser system can be controlled. The filter feeds the positioners with filtered oil. Activating the remote control and the signal horn. but as soon as you have selected remote control operation. User interface .Microprocessor ② • This is the user interface for SPACE 3000 (Pro cranes) or SPACE 5000 (HiPro cranes). As soon as the operator moves a lever the valve closes. 3 Remote controller CombiDrive2 (HiPro cranes) ⑥ • The controller is the device that the operator use to control the crane. System ON: the lamps light up Remote control ON: the lamps blink 90% of maximum permitted load and OLP: the lamps flash twice Operator's Manual GB 41 . There is also an emergency stop button on the controller. Selector valve ⑦ [not applies] • Select the oil flow towards either the crane or the stabiliser system. amber and red. green: start up remote control amber: prewarning OLP amber and red: OLP Warning lamp ⑨ [option] • A warning lamp on each stabiliser leg is used to warn the surrounding about ongoing activity. Lamp pole ⑧ [option] • The lamp pole is equipped with 3 lamps. Flashing/light up: green. by amber light indication.The Safety system 4. A warning lamp also gives information to the operator about the different statuses of the crane. 42 Operator's Manual GB .4 4. When the oil flow is insufficient. the oil flow is allocated by means of PFD.The Safety system 4. When remote control is used. one or more functions might reduce their speed.4 • • • • • • • • Operating components 4.5 main control valve V91 stabiliser control valve extra stabiliser control valve [option] selector valve [option] high seat [option] Pro: user panel SPACE 3000 HiPro: user panel SPACE 5000 HiPro: remote control CombiDrive2 with radio with cable connected Main control valve The speed of a function corresponds to the extent of the lever movement. as long as the oil flow is sufficient. regardless of the load and other functions. 5 Main control valve lever function Operator's Manual GB 43 .The Safety system 4. 4. 1 3 ➁ ➀ 44 Operator's Manual GB .6 4.6 The Safety system Stabiliser control valve The stabiliser control valve is equipped with 2 levers on each side of the crane. The levers have the functions: ➁➀ 1 1 1 1 • Stabiliser leg ① upward/downward • Stabiliser extension ② out/in The stop button affects the oil supply to this valve. 7 Extra stabiliser leg [option] The stabiliser leg valve is equipped with 8 levers The levers have the functions: ➁ ➃ ➀ ➂ • Stabiliser leg ① upward/downward • Stabiliser extension ② out/in • Extra stabiliser leg ③ upward/downward • Extra stabiliser extension ④ out/in The stop button affects the oil supply to this valve.7 4.The Safety system 4. 4.8 Selector valve [option] Use lever ① to select: ➃ ➂ ➁ ➀ ➀ • Crane functions: manual or remote • Stabiliser system functions Operator's Manual GB 45 . 9 Cranes with high seat [option] The high seat is equipped for using tools and operated by two joystick levers: ① and ②. DANGER Take care not to put your foot on the pedals when taking place in the high seat. 46 Operator's Manual GB 1 3 4 2 . The control valve is placed at the high seat. The controls have the functions: • Joystick ① First boom: downward/upward Add-on equipment • Joystick ② Second boom: downward/upward Add-on equipment • Pedal ③ Extension boom: out/in • Pedal ④ Slew: clockwise/counterclockwise For safety reasons. Hydraulic stabiliser extensions and legs are controlled by an additional control valve fitted to the stabiliser beam. it is necessary to sit down on the seat to operate the controls. Unintentional crane movements can occur.The Safety system 4. and two foot pedals: ③ and ④.9 4. if present. while manually operating the crane. • Button ③ Push the button to operate stabiliser extensions and legs. all crane movements are stopped immediately. SPACE 3000 ➁ ➂ Operator's Manual GB ➀ ➃ ➄ 47 .The Safety system 4. The button is also an OLP release button with the functions: Disconnecting the automatic dump function. The OPS system is integrated in the SPACE system.10 4. 4. to sound the horn. OLP release.11 User panel SPACE 3000 Manually controlled cranes are equipped with user panel SPACE 3000 Functions: • Stop button ① When you push the stop button. • Button ④. to switch the manual extensions on/off. and it uses a sensor on the rack and tilt indicators on the boom system. • Button ⑤ Push the button.10 OPS Operator Protection System [option] • OPS is a system that protects the operator from the boom system's movements when operating the crane. • ON/OFF button ② to switch the safety system On/Off. to indicate the position of the crane. It creates a virtual cage around the area where the crane operator stands. VSL [option] or stabiliser leg [option]) Red light blinking: OLP Release (crane. crane stops.1 Indicator lights on user panel SPACE 3000 ➇ ➆ D D A BC C B ➁ A ➅ ➄ ➉ ➀ SPACE 3000 ➃ ➈ Power On ① Green light on: The system is on. Diagnostic required. Green light flashing: An emergency stop button is depressed or remote control selected. Red light flashing: Critical error is stopping the crane. Service ② Green light on: Time to service the crane. OLP Release ③ Red light on: OLP (crane. Stabiliser leg set to ground.The Safety system 4. Green light on: Stabiliser extensions fully out and legs set to ground. VSL [option] or stabiliser leg[option]) Green light on: dump 2 active (if present) OLP Release ④ OLP Release ③ Green light on both ③ ④: Stabiliser functions are activated ④ (dump 1 and 2 active). Operator's Manual GB . Red light dubble flash: CAN Error. Red light on: Stabiliser leg overload.11.11. Green light on: Increased capacity (ADC mode). ⑦ Not active. Lamp blinking: Stabiliser extension is not fully out.1 4. Red light on: A non-critical error detected in the system. Stabiliser leg/extension [option] ⑤ Automatic duty control ⑥ Hoist LED 48 ➂ Green light on: Dump 1 active. reduced capacity. type CombiDrive2 and control valve type V91 are equipped with user panel SPACE 5000: Functions: • Stop button ① When you push the stop button. Green light A . normal capacity. Red light on: VSL OLP. Green light A on: 50% of OLP pressure. Vehicle has reached a stability limit.D on: 100% of OLP pressure. Lamp test for the user panel SPACE 3000 See: Daily inspection. crane capacity is not fully used.12 Cylinder pressure LED's ⑧ Manual extension ⑨ Not active. • Button ③ with the symbol To switch on the remote control and radio control. all crane movements are stopped immediately. Vehicle has reached a stability limit. ➁ ➂ ➀ ➃ ➄ • Button ④ with the symbol To select manual function. 4. Slewing sector [option] ⑩ Green light on: Outside slewing sector. VSL: Variable Stability Limitation [option] ⑩ Green light on: Full VSL stability. (Also all the 1st boom diodes will light red).The Safety system 4.C flashes: 90% of OLP pressure. • Confirm view button ⑤ with the symbol Operator's Manual GB 49 .12 User panel SPACE 5000 Cranes with remote control. Red light on: OLP. • ON/OFF button ② with the symbol to switch the safety system On/Off. Light off: Inside slewing sector.B on: 70% of OLP pressure. Red light blinking from A to D: OLP Release. Red light A . Red light A . (Also all the 1st boom diodes will light red). Light off: Vehicle has limited stability but. Light off : Vehicle has limited stability but. Diagnostic required. (Also all the 1st boom diodes will light red). Vehicle has reached a stability limit. Red light flashing: Critical error is stopping the crane. Operator's Manual GB . crane capacity is not fully used. Green light flashing: An emergency stop button is depressed. VSL: Variable Stability Limitation [option] ④ Green light on: Full VSL stability. Red double flash: CAN error. reduced capacity. Red light blinking: OLP release button has been pressed. Red light on: VSL OLP. Red light on: A non-critical error detected in the system.The Safety system 4. 5 sec to release OLP. Red light on: OLP. Vehicle has reached a stability limit.12. Slewing sector [option] ④ Light off: Inside slewing sector. (Also all the 1st boom diodes will light red). 4. crane stops.12. Service ② Green light on: Time to service the crane. Automatic duty control ⑥ Green light on: Increased capacity (ADC mode) Hoist LED ⑦ Not active.1 To confirm full view of operating the stabiliser extensions outward.1 Indicator lights on user panel SPACE 5000 ➆ ➁ ➇ ➅ ➉ ➂ ➃ ➀ ➈ 50 ➄ 11 A BC D C B A D AB CD 12 Power On ① Green light on: The system is on. OLP Release ③ Red light on: OLP. Red light blinking: Radio interference.The Safety system 4. connection.12.1 Cylinder pressure LED's ⑧ Remote control ⑨ Manual extensions ⑩ Not active. Green light blinking: Stop button pressed/no radio. Green light A on: 50% of OLP pressure. Green light on: Remote control. Stabiliser system ⑪ ⑫ Green light on: The stabiliser system is ready to use. Red light blinking from A-D: OLP release. Red light A-C flashes: 90% of OLP pressure. Manual control ⑪ Green light on: Manual control. Good radio connection. Green light A-B on: 70% of OLP pressure. Operator's Manual GB 51 . Red light A-D on: 100% of OLP pressure. 13 CombiDrive2 Normally the controller operates wirelessly via radio but it can also be operated via cable Via radio: The controller contains a radio for two-way communication.4.4 GHz band. as well as indicating the radio reception conditions. The side displays show the symbol for the function which each lever activates in the chosen menu. The controller is equipped with a menu selection system as standard. Via cable: A four-metre cable is supplied as standard with the radio kit of the controller. The centre display provides information about which menu has been chosen. manual extension. When the operator changes menu. ADC. including across national boundaries. the symbols change to the functions that become active. and so on. The display continuously provides the operator with information. fault information. battery status. micro.13 The Safety system 4. This means that information can be sent both from and to the controller. The cable is intended to be used for short-term operation and when pairing in conjunction with the replacement of controllers or decoders. In the decoder/radio there is a corresponding unit which handles the traffic at the other end. The cable connects to the vehicle at the left-hand CAN bus connector on the decoder. To give the operator greater freedom of movement. If the controller is to be wired permanently or for a long period. an adapter cable is connected from the user panel and installed at a suitable location on the vehicle. This is a free band which has been approved practically world wide. No licence is needed and the radio can in principle be used everywhere. 52 Operator's Manual GB . a 15-metre cable is used between the adapter and the controller. The radio is of the “Bluetooth” type and therefore operates in the 2. Signal strength The bars show the radio signal strength. Five bars indicate optimum reception conditions. it should be stored in a compartment where the temperature exceeds +10°C. The number shows the relevant sub-menu of that main menu. If the symbol flashes. When the symbol begins to flash there is capacity for just a few more minutes. In order to prevent accidental menu shifts in cold weather. The symbols for signal strength (radio) and battery capacity are replaced with the symbol for cable operation. Low ambient temperature 4. there will be a time delay before any menu button will react to a second depression. The main menus are CRANE. the centre display indicates that the controller is in cable operation mode. Main menu This text shows which main menu that has been selected. When this happens the horn on the crane will beep twice as an indication of low battery. it will take approximately 1 s.13 CRANE 1 CRANE 1 The LCD-type displays on the controller are somewhat slow in changing state under low temperature conditions. At 0°C. In order to avoid this inconvenience. which could give an acoustic signal to emphasize the warning and make the operator aware. EXTRA and ON-OFF. HIAB recommends that whenever the controller is not in use. and at -20°C it can take up to 8 s before the symbols are completely changed. the radio is connected but the starting conditions are not met. Centre display Centre display View modes The centre display as it appears when the controller is started. Battery capacity The battery symbol shows remaining energy in the battery. Alternating symbols will not be updated at temperatures below freezing. This information is intended for the Safety System. below -10°C. Operator's Manual GB 53 .The Safety system When the cable is connected to the controller. 4. has discovered a fault in the system. are shown. Alternating symbols will not be updated at temperatures below freezing. 54 Operator's Manual GB ADC Enlarged Normal size . μ50% is 50% of normal speed and µ20% is 20% of normal speed. a spanner. Microoperation changes the resolution of the levers as follows: At full lever deflection. Fault indication. this information must be sent to Safety System. the symbol is enlarged for three seconds. it is enlarged for three seconds in the upper part of the centre display. The error codes scroll up on the centre display at the same rate as the Safety System. If there are more than six error codes at the same time. appears if the Safety System. has the possibility to send error codes to the controller. the fault symbol a spanner appears. Fault indication. Safety System. the six most recent ones sent from the Safety System. When the symbol appears. It then returns to its normal size. Micro Indicates that micro operation has been selected.Not critical If a fault is detected in the control or Safety System. the centre display changes state to show the error codes. ADC Indicates that the ADC function is active. acknowledges by showing this symbol. By pressing the info-button. This is to show the operator that a change has happened.Critical The fault symbol spanner appears enlarged and becomes large. Micro / adc / manual extension indication When one of the above functions is activated or engaged. The crane stops. Error code display The Safety System. sends them.13 The Safety system Centre display View modes Error This symbol. Manual extension If manual extension is used. it is disabled.g.14 Info-Button Use this button for changing the centre display window. If a lever is faulty. e. There are three main menus which the operator can toggle between with three pushbuttons: • CRANE menu button ① • EXTRA menu button ② • ON-OFF menu button ③ ➀ In each of the main menus the operator can step through submenus by pressing the same button repeatedly.The Safety system 4. without shifting main CRANE menu. with six or eight levers. 1-2-3 and then back to 1 again. The restriction is that one function is only present on a specific lever. 4. it it possible to use the seventh and eighth functions simultaneously with functions 1-6.14 Main menus CombiDrive2 There are two versions of CombiDrive2. The other levers operate in the usual way. Operator's Manual GB ➁ ➂ 3 2 1 55 . Lever 1 to 6 (or 8) (display symbol shows direction of operation with lever forward) The functions of each lever may be the same or different in different menus. or if it is deflected on startup. With the 2 extra levers on the 8 lever controller. When the menu changes. The submenus in “CRANE” mode are configured in production but can be changed by HIAB service personnel. Symbols for the 8 lever controller: Left side display Centre display "CRA NE MENU " 3 2 1 56 Operator's Manual GB ➀ Right side display . by pressing the CRANE menu button. it always starts in CRANE 1 menu. The symbols are stored in a symbol library and can be configured/set via the terminal program for a CE crane.4. the symbols change and the functions are activated in the current menu.14 The Safety system Menu: CRANE CRANE menu button When the operator pulls out the stop button on the controller. This appears in the left or right display. For every lever there is a corresponding function which it controls. The Safety system 4.14 Symbols for the 6 lever controller: Left side display Centre display Right side display "CRANE MENU" 3 2 1 Operator's Manual GB 57 . For the 6 lever controller: If the crane has 1 stabiliser control valve. on the controller 2 Left stabiliser extension out 3 Left stabiliser leg down 4 Right stabiliser extension out 5 Right stabiliser leg down Operator's Manual GB 5 6 . The function is logically positioned in relation to the lever.14 Menu: EXTRA EXTRA menu button This button activates the EXTRA menu. The order of the levers is customized. boat supports. etc. The symbols are configured in the same way as for the “CRANE” main menu. These display symbols must match the function being used. The same method is used for stepping between the sub-menus. the order of the levers should be: EXTRA 2 1 2 3 4 Lever 58 Functions.The Safety system 4. Left is defined as the side of the crane where the main control valve is normally placed. The “EXTRA” main menu contains hydraulically proportional functions for example front and rear stabiliser extensions and legs. lever forward. bunk shifting. lever forward. on the controller 3 Left stabiliser extension out 4 Left stabiliser leg down 5 Right stabiliser extension out 6 Right stabiliser leg down Operator's Manual GB 59 . lever forward.The Safety system 4.14 If the crane has 2 stabiliser control valves. the order of the levers should be: 1 Lever 2 3 4 5 6 7 8 Functions. on the controller 2 Right crane stabiliser extension out 3 Right crane stabiliser leg down 4 Right auxiliary stabiliser extension out 5 Right auxiliary stabiliser leg down For the 8 lever controller: If the crane has 1 stabiliser control valve. on the controller 2 Left crane stabiliser extension out 3 Left crane stabiliser leg down 4 Left auxiliary stabiliser extension out 5 Left auxiliary stabiliser leg down Menu 3: Lever Functions. lever forward. the order of the levers should be: Menu 2: Lever Functions. on the controller 1 Left auxiliary stabiliser extension down 2 Left auxiliary stabiliser leg out 3 Left crane stabiliser extension down 4 Left crane stabiliser leg out 5 Right crane stabiliser extension out 6 Right crane stabiliser leg down 7 Right auxiliary stabiliser extension out 8 Right auxiliary stabiliser leg down Operator's Manual GB .4. lever forward. the order of the levers should be: Lever 60 Functions.14 The Safety system If the crane has 2 stabiliser control valves. stop and throttle. Only ordinary numerals and the letters of the English alphabet can be used. Currently there are no symbols for these functions. "ON-OFF MENU" Left side display 2 1 Centre display FRONT LIGHT REAR LIGHT ON-OFF 2 ENGINE START ENGIN E STOP ON-OFF 1 Operator's Manual GB Right side display PUMP 1 PUMP 2 ENGINE RPM UP ENGINE RPM DOWN 61 . The functions are controlled by levers 2 – 5. A lever may be deflected in any direction in order to activate the corresponding function. The “On-off” main menu includes functions such as start. Instead. For each sub-menu.The Safety system 4. four functions may be defined. The functions are configured by the bodybuilder.14 Menu: ON-OFF ON-OFF menu button This button enables the on-off functions. text can be entered directly into the window that corresponds to each function. 6V and 7. ① and ② lights during charging. Note that the battery voltage remains between 7. Two batteries are delivered with each unit.0 there is error in the battery: Change battery. A charged battery The voltage level of a fully charged battery is approximately 8. where there is a risk of a short due to metal components.4). Used batteries should be taken care of according to the local regulations. the battery voltage cannot be used to estimate the working time.15 Battery charger CD2 The battery charger is to be fitted in a protected environment. Operating ambient temp: Battery = 0° to + 45°C.5V for a long time. The battery charger is designed not to damage the battery. NOTE A charged battery is a concentrated energy source. Therefore. 62 Operator's Manual GB ➀ A ➀ ➁ ➀ B ➂ . ① and ③ lights when the battery is fully charged. one of which can always be placed in the charger.The Safety system 4. is approximately 3 hours. Charging time The normal charging time for an flat battery.15 4.4V and it provides about 5-8 hours working time. When the display blinks 0. Display A ① lights when the charger is activated. Never store a charged battery in a toolbox or similar. Display B Shows the battery voltage (8. preferably in the cab. even during long continuous charging. this function diverts the oil to the tank.16 Installing the battery Install a fully-charged battery in the controller as shown on the right. Release the buttons. thereby preventing the oil from overheating. The most common case is before operating a separate stabiliser control valve (which is not equipped with spool sensors) Operator's Manual GB 63 . Keep the buttons pressed while pulling out the stop button. Locking the controller • Press buttons “EXTRA” and “ON/OFF” while the stop button is pressed. ADO Automatic dump function If a lever is not moved for 3 seconds. A fully charged 1200 mAh battery will power the controller for approximately 5 hours. Disconnecting the automatic dump function (ADO) In certain cases the automatic dump function must be disconnected. The controller is ready to use. such as children. • Keep the buttons pressed while pulling out the stop button.16 Functions Locking / unlocking the controller The controller can be locked to prevent unauthorised persons. If the battery is upside-down the controller will not start.The Safety system 4. from starting the controller and operating the crane. 4. The next lever movement stops the dumping and it functions as normal. It is important to fit the battery the right way round. The centre display then shows a large locked padlock symbol Unlocking the controller Press buttons “EXTRA” and “ON/OFF” while the stop button is pressed. smooth simultaneous operation is achieved. 64 Operator's Manual GB ADC ➁ . the lifting capacity is increased during the complete lifting cycle. The automatic dump function is now connected again. The first boom pressure sensors indicate if there is a positive or negative pressure on the first boom. Increased capacity (ADC mode) • ADC lamps light up. the sensors indicate a negative pressure and the lifting capacity is normal during the complete lifting cycle. PFD will now take over. reducing the speed of all operated functions. Press the Button ① again. the automatic dump function is always connected. If the sensors indicate a positive pressure. Normal capacity • If the first boom is pressed down. normal speed is restored. ADC Automatic Duty Control The purpose of the ADC function is to increase the lifting capacity by 10%. When the power is switched on.4. Uncontrolled movements are thus avoided. When the load decreases. Press the Button ①.16 The Safety system To disconnect the automatic dump function: 1. ASC Automatic Speed Control ➀ The ASC function automatically provides the extra power by reducing the speed smoothly. The LED ② is lit constantly when automatic dump function is disconnected. PFD Pump flow distribution When operating several functions simultaneously the pump flow may not be sufficient. when working close to the rated capacity. 2. 16 Controlling crane speed Use the micro button to change resolution of the lever to 50% or 20% of normal speed. In case of an overload warning you may slew out of the sector but not further into it.The Safety system 4. lifting capacity can be reduced due to stability. The overload warning will be given at a lower load in the limited sector than outside the sector. and automatically calculates the level of OLP limit. Slewing sector [option] Within slewing sector. VSL Variable Stability Limitation [option] The VSL function senses the outreach and the attachment of the stabiliser legs to the ground. Operator's Manual GB 65 . This means that the crane always works with the highest possible lifting capacity in relation to the stability. The vehicle inclination (α) during crane operation must not be more than allowed in the Technical Data for your crane. unintentional crane movements can occur. When the bubble is between the two circles. check the spirit level on the crane.Starting crane operation 5 5. To determine the inclination of the truck. If the slope exceeds the permitted inclination. the crane inclination is between 0° and 5°. 66 Operator's Manual GB 60° 60° . NOTE • Operating the crane in to and out of parking position must also be done with the vehicle completely levelled. When the bubble is in the middle of the gauge.1 Starting operations Placing the vehicle • General case: Place the vehicle on a flat surface. the vehicle has to be completely levelled in any direction. the crane is in horizontal position. 0° 3° 5° α 0° α α 0° α • Particular case: Working with boom system beyond 60° To avoid side deflection and in order to guarantee the safest operation when working with the boom system beyond 60º. press the On/Off button on the user panel. To activate the system. Rpm too low: during crane operation. NOTE • Rpm too high: the oil in the hydraulic system might overheat.Starting crane operation 5. The LED above the button starts to blink. • The maximum rpm may depend upon a governor on your PTO combination. CD2 Start the safety system The operating levers must be in neutral position before start up.1 Engage the PTO • Engage the PTO (Power Take Off). Operator's Manual GB 67 . The system will check itself (2-4 seconds) The warning lamps [option] on the stabiliser legs light up. • Bring the vehicle's engine to the correct rpm. the vehicle's engine could stall. in the most comfortable operation position. CRANE 1 menu and signal strength are displayed. 68 Operator's Manual GB . Radio link established ➂ ➁ ➀ • When the radio link has been established. LED ① is lit. “Wait” is displayed while radio contact is being established. The Stop button should be on the right hand side. The LED ② on the decoder starts to blink.5. or shoulder-/neck strap.1 Starting crane operation Remote control CD2 1. 2. To activate the controller. LED ② on the decoder gives a steady light and LED ① flickers. Press the remote control button on the user panel. 3. The radio starts to establish a link with the decoder.The green lamp on the lamp pole [option] lights. pull out the stop button by turning it clockwise. Decoder LED’s colour: ① green ② yellow ③ red The decoder is powered on when remote control is chosen. The diode above that button gives a steady light. Fasten the contoller to a waist belt. • On the controller. Starting crane operation 5.1 Cold starting CD2 The connection time for cold starting may be as much as five seconds. Cold starting means that the controller has been in stand by mode for the last ten minutes. If you restart the controller within ten minutes, the radio link is still established and the controller is ready for immediate use. (Ten minutes is default value but can be set to a value between one and thirty minutes.) The controller will always start in CRANE 1 menu, regardless of which menu was active when the controller was stopped. Operating the stabiliser system DANGER When you are operating the stabiliser extensions: Make sure that you have full view of the stabiliser extensions. Do not stand in front of the stabiliser extensions. Remote control - manual controlled stabiliser extensions and legs: Without selector valve: • Press the button and the button . or • Press the button for EXTRA menu. Now operate the stabiliser extensions and legs manually. Operator's Manual GB 69 Starting crane operation 5.2 If selector valve [option]: If the crane has selector valve move lever ① to stabiliser system position. 5.2 Extend stabiliser extensions and set stabiliser legs To ensure the full crane capacity, all the stabiliser extensions and legs must be fully extended and set to the ground. NOTE The stabiliser leg's downward movement is automatically stopped at a given force level. To exceed this force level, operate the stabiliser leg down once again. WARNING Take care not to lower the stabiliser leg to your foot. DANGER Check that the support plates do not bend or sink into the ground! WARNING Always ensure that the stabiliser legs and stabiliser extensions are in working position and securely locked. 70 Operator's Manual GB ➀ Starting crane operation 5.2 Operation with non-tiltable stabiliser legs: Unlock the catcher ①. Extend the stabiliser extension. Position the loose leg support plate onto the ground (if delivered). 4. Set the stabiliser leg to the ground. Repeat for the stabiliser extension and leg on the other side of the vehicle 1. 2. 3. When there is an additional set of stabiliser legs [option]: Repeat the process for the 3rd and 4th stabiliser legs. ➀ Operator's Manual GB 71 3 Operate the crane out of parked 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 add-on equipment carefully. push button CRANE MENU on the controller to change the menu into crane operation. push the remote button on the user panel. ➀ DANGER Always operate manually controlled crane from the position indicated ! 72 Operator's Manual GB . 2.Starting crane operation 5.3 5. If stabiliser system is under manual control. If using remote controller. Once the stabiliser extensions and legs are ready you can start using the crane: 1. Starting crane operation 5.3 If selector valve [option]: If the crane has selector valve move lever ① to crane position. ➀ Operate the boom system 1. 2. 3. Raise the first boom. Slew the crane to the working position. Extend the hydraulic extensions. The crane is now ready for use. NOTE As soon as you have selected remote control operation, it is impossible to operate the main control valve levers. Operator's Manual GB 73 During operation 6 6.1 OLP (Overload protection) OLP HiPro crane The OLP function is a safety function in SPACE that prevents overloading of the crane. With 90% of maximum permitted load, a prewarning is given. The warning lamp [option] on the stabiliser leg double blink and the cylinder pressure LED's flash red. The yellow lamp on the lamp pole [option] flashes and the cylinder pressure LED's flash red. When 100% of the maximum permitted pressure is reached, the OLP cuts in. The display shows whether a particular motion is prohibited or if the crane is subject to OLP. The warning lamp [option] on the stabiliser leg will flash twice , the red and the amber lamps on the lamp pole [option] will light all the time and the cylinder pressure LED's will light continuously. 74 Operator's Manual GB 100% During operation OLP Boom system Warning at 50%, 70%, 90% and 100% visible on the controller • The pressure in the cylinders is displayed as a percentage of the maximum permitted pressure. • The percentage pressure loading in the cylinder is displayed in the window of the respective lever as a number: 50%, 70%, 90% and 100%. • When the pressure is 50% or more, the percentage alternates with the lever symbol once a second. • When a pressure sensor reaches 100 %, all motions that would increase torque are blocked. • If the operator attempts to activate a blocked function, the function symbol is replaced by a cross while the lever is deflected. When the lever is returned to the neutral position, the cross disappears and the information returns. Operate permitted (load reducing) functions only. 6.1 50% 70% 90% 100% NOTE Do not operate heavy loads with the extensions fully retracted. In an OLP situation it is an advantage to be able to retract the extensions. Warning at 50%, 70%, 90% and 100% visible on the user panel • Indicator lamps ① are flashing on the user panel when load is close to rated capacity and light up at rated capacity. Operator's Manual GB ➀ 75 The display symbol goes back to normal. slewing is stopped in the direction towards the stabiliser leg where the OLP occurs. The centre display is viewed 100% and the symbol for which leg has overload. Move all the levers to neutral and operate permitted (load reducing) functions only. The crane stops. The VSL indicator lamp light red on the user panel.6.1 During operation OLP Stabiliser system [option] If a stabiliser leg is overloaded. 100% CRANE 1 76 Operator's Manual GB EXTRA 2 . VSL CRANE 1 100% To release OLP (CombiDrive2) In certain OLP situations. the first and second booms can be locked. During this period it is possible to operate an appropriate crane function so as to correct the overload situation. The display symbol goes back to normal. by pressing the release-button on the right hand side below the display handle.1 VSL . The slewing is stopped towards the instability direction and the crane stops. Extension out cannot be operated. There is a waiting time before the release operation can be activated again. Move all the levers to neutral and operate permitted (load reducing) functions only. The VSL indicator lamp light red on the user panel. 60 and maximum 90 seconds (the time starts to count down as you move the lever).OLP [option] VSL-OLP occurs when there is a risk of instability of the vehicle. Operator's Manual GB 77 . Only one unallowed function at a time can be operated.During operation 6. The unlocked padlock will appear in the centre display. The time increase in three steps: 30. It is then possible to release the OLP for approximately 5 seconds. The 100% symbol in the left display alternates with OLP for crane. The centre display indicates VSL. all movements will stop. Never use the OLP override to overload the crane deliberately! 78 Operator's Manual GB . The crane will be fully operational as long as only allowed movements are used.During operation 6. DANGER Only use the OLP override to get the crane out of a locked position. Manual control If one prohibited movement is used.1 On the user panel the cylinder pressure LED’s and the lamp for padlock symbol will flash red. Remote control .1 7 Operate the crane to parking position WARNING • A crane with add-on equipment can differ from the operations described in this section.Ending crane operation 7. 2. Operator's Manual GB 79 . During folding. always operate the crane manually from the position indicated in the figure. Lower the boom system against the vehicle. 3. • For this reason. Now operate the stabiliser extensions and legs manually. or • Press the button for EXTRA menu. 1. (Do not extend the second boom cylinder fully). study the operating instructions for any add-on equipment carefully.manual controlled stabiliser extensions and legs: Without selector valve: • Press the button and the button . Slew the crane until the crane is parallel to the vehicle. Retract the extensions completely. WARNING Do not put your foot on the support plate. Operator's Manual GB ➀ . 7. 2. Operation with non-tiltable stabiliser legs 1.4 Placing the stabiliser extensions and legs in transport position Activate operation of stabiliser extensions and legs.Ending crane operation 7. 80 If loose support plate delivered. if not. Retract the stabiliser leg.4 If selector valve [option]: If the crane has selector valve move lever ① to stabiliser system position. rectract a little the stabiliser leg. 4. Retract the stabiliser extension completely. DANGER Do not stand in the stabiliser legs. DANGER Always ensure that the stabiliser legs and the stabiliser extensions are in transport position and securely locked. tilting area. Unlock the loose support plate. 3. go to step 3. Break the security sealing on dump valve 1 on the inlet section. 7. 7. 3.5 The catcher ① will lock the stabiliser extension. When there is an additional set of stabiliser legs [option]: Repeat the process for the 3rd and 4th stabiliser legs. Operate the crane to parking position using the levers on the main control valve. Press the dump valve button and turn 90 degrees until it is blocked. Operator's Manual GB 81 .5 Switching off the safety system ➀ • Push in the stop button and switch off the safety system. Repeat for the stabiliser extension and leg on the other side of the vehicle 5.6 Emergency operation Valve-V91 EMERGENCY operation to bring the crane to parking position Do like this: On the main control valve: 1. 2.Ending crane operation 7. • Disengage the PTO. the indicator lamps for both the cylinders and the hoist will flash red for a while. Operate the stabiliser extensions and stabiliser legs to parking position using the levers on the stabiliser control valve. on the outlet section. 1. 2. 82 Operator's Manual GB .Ending crane operation 7. 7.7 Separate stabiliser control valve: The button on dump valve 1 on the main control valve is to remain depressed. Press the dump valve button and turn 90 degrees until it is blocked. 3. Always go to/contact a HIAB service workshop when the seal wire has been broken. The vehicle must not be moved. and/or if the first boom angle exceeds a certain specified angle.7 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. DANGER To operate the crane like this is HIGHLY DANGEROUS because during emergency operation all crane security is disconnected. The dump valve 2 is placed on the main control valve. Break the security sealing on dump valve 2. Operator's Manual GB 83 . indicates when the crane height exceeds a predetermined maximum and when the manual operated stabiliser extensions/tiltable stabiliser legs are not locked in the transport position.Ending crane operation 7. 2. visible and audible from the driving position for transport.7 • A warning. secure the boom and the lifting accessories to prevent any unintentional movement of the crane and the lifting accessories. Switch off the system. or over the load. put the crane into the transport position. • The audible warning can be silenced by an acknowledgement button [option] or by a signal indicating that the parking brake of the vehicle is engaged. Switch the system on. The vehicle must not be moved 1. DANGER After use always put the crane into the transport position! When you have to park the boom on the load space. The vehicle may be moved. Place the earth connection as close as possible to the welding spot. 5. 84 Operator's Manual GB .1 Service DANGER • Do not do any welding work on the crane yourself! Welding work on the crane may only be carried out by. After this. or in close consultation with. 3. Before carrying out any welding on the vehicle 1. a HIAB service workshop. Drilling work on the crane may only be carried out by. Disconnect the PLUS cable. Connect the MINUS cable. Switch off the operating system. 4. • Never try to reinstall the crane. 2.Only a HIAB Dealer may reinstall the crane. • Do not drill into the crane yourself. Disconnect the MINUS cable. 2. Connect the PLUS cable. the welding work can be carried out After welding on the vehicle 1.Maintenance and Service 8 8. or in close consultation with. a HIAB service workshop. and original HIAB parts have been used. The oil in the hydraulic system is under high pressure. Deal with an oil leak as follows: 1. Disengage the PTO. If you can: fold the crane and go to a HIAB service workshop. 5. If you cannot: contact a HIAB service workshop.2 Warranty HIAB only provides a warranty if: • The instructions for maintenance and service have been followed. If tightening does not help: contact a HIAB service workshop.Maintenance and Service 8. Rest the crane on the floor or on the truck platform. 4. 2. In all other cases.2 Leakage DANGER • Keep well away from an oil leak on the hydraulic system! The oil spraying out can cause serious injury. • Do not replace any hydraulic hoses or lines yourself: Precautions shall be taken when disconnecting hydraulic lines and hoses to ensure that no hydraulic pressure is retained in the line when the power supply to the system is switched off. Leaking coupling: Tighten the coupling with a spanner. Operator's Manual GB 85 . 8. • Always contact a HIAB service workshop. contact a HIAB service workshop. Small leak on a a line or hose: Determine if you can still fold the crane. Switch off the operating system. 3. Pressure may be retained in the hydraulic lines when the power supply has been switched off. 6. WARNING • Ensure that faults in the crane are corrected immediately! • Never correct faults yourself that may only be corrected by a HIAB service workshop. Only the cranes surface may be cleaned with a high-pressure jet cleaner. If the crane is not be used for 1 month or longer: • Lubricate the crane thoroughly. signs. Cleaning Clean your crane and accessories regularly. Always use original HIAB parts and tools. to a HIAB service workshop for inspection and maintenance. at least once a year.Maintenance and Service 8. Maintain lifting accessories according to the supplier’s instructions. • Never use a high pressure jet cleaner on electronic parts. Filters Replace the filter cartridge • after the first 50 hours operation • then after every 500 hours operation • or at least twice a year. but: • Do not use aggressive cleaning agents. control valves. cylinders or the oil tank. 86 Operator's Manual GB . plastic components.3 Follow the maintenance instructions! Take the crane. • Park the crane in the transport position. according to the lubrication schedule. • Carry out yourself only the service and maintenance work you have the requisite knowledge and experience of. 8.3 • All seals on the valves are still intact. bearings. Stop buttons • Check that the Stop buttons are undamaged and working properly. shaft lockings. Electronic components • Check that these are in good condition. Hook. Hydraulic system • Check that there are no leaks from the hydraulic hoses. bearings and bushings are undamaged and working properly. • Have the damage repaired immediately by a HIAB service workshop. Levers • Check that the levers operate smoothly.3. lines and connections. • Check that the levers return to the neutral position. bearings and bushings • Check that the shafts.1 8. any formation of cracks). If red replace the cartridge. Shafts. DANGER In the event of damage that presents a safety risk: • Do not use the crane.Maintenance and Service 8. shaft lockings. Operator's Manual GB 87 .3.g.1 Daily inspection Stabiliser locking devices • Check that the stabiliser locking devices are undamaged and working properly. Filters • Check the filter indicator. Crane structure • Check for damage to the crane structure (e. hook lock and hook suspension • Check that these are in good condition. 2. all the green the LED's are illuminated. The test is finished when all LED's is extinguished. the chromed surfaces must be cleaned and oiled to prevent corrosion.2 Monthly inspection and maintenance In addition to the daily inspection. all three lamps will light. Piston rods • In cases where the cylinder piston rod is exposed to pollution due to the parking location. If the system is equipped with lamp pole.3.2 Maintenance and Service LED test To do the test: 1. The test is activated and all the red LED's are illuminated. This needs to be done regularly. top up.8. top up. Oil tank level • To check the level in the oil tank: Place the vehicle on level ground with the crane in transport position. auxiliary equipment etc. Add-on equipment • Maintain all add-on equipment. Release the button. according to the instructions supplied with it. 8. Press the ON/OFF button for at least 2 sec. carry out the following each month. • If necessary. 88 Operator's Manual GB . After 3 sec.3. • If necessary. Slewing housing oil level • Check the oil level in the slewing housing. Lubrication schedule • Carry out the lubrication according to the instructions.2 Presence of load plates and notices • Check that the symbols near the levers for the main control valve and stabiliser control valve are in position. Cables and sensors on the boom system • Check that these are in good condition. Operator's Manual GB 89 . Bolts and screw fixings • Check that bolt and screw fixings are tightened. play.Maintenance and Service 8.3. • Or have the oil tested by a workshop or specialist. loading diagram. Hydraulic system oil • Check if the oil in the hydraulic system should be changed. Pivot pins and bushes • Inspect all the pivot pins and bushes for the crane boom and cylinders for damage. etc. • Maintain all add-on equipment. • Check that all other notices and stickers are in position: load plates. according to the instructions supplied with it. Add-on equipment etc. Hydraulic pump fixing • Check the hydraulic pump attachment underneath the vehicle. warning symbols. auxiliary equipment etc. NYNÄS UNIFETT EP. If you not do so. depending on the climate). Recommended greases: BP LS EP 2. at least once a year.3 8. Type of grease Use lithium based grease containing EP additives (consistencies 2 and 3 are recommended. ESSO UNIWAY EP2 N. Hydraulic oil • Change the hydraulic oil. Or have it tested by a workshop or specialist. Carry out the following maintenance at least once a year.4 Lubrication WARNING Follow the lubrication schedule exactly. 8.3. NOTE Avoid grease with graphite or molybdenumdisulphide additives. 90 Operator's Manual GB . • Replace filters. AGIP GR MU/EP3. to a HIAB service workshop for inspection and maintenance. Oil in the slewing housing • Change the oil in the slewing housing Hydraulic system oil tank filler cap • Change the filler cap. there may be serious damage to the crane and to add-on equipment.3.Maintenance and Service 8.3 Annual maintenance Take the crane. A: Internal pads B: Internal guides See chapter of Slewing housing Lubrication A B B 8. • Retract the extensions.Maintenance and Service 8.4.1 Lubrication schedule Lubricate after every 16 hours of use. Front upper slide pads • Extend extensions with load in order to create enough clearance.4.4.1 8.2 Lubrication of slide pads in boom system Rear upper slide pads • Extend the extensions until you can see the slide pad through the hole. Lubricate after every 50 hours of use. Operator's Manual GB 91 . • Lubricate. • Lubricate. 92 Operator's Manual GB ➀ ➁ . • Slew the crane a little. until the column has been slewed round completely. Niples ①: For greasing upper column bearing Niple ②: For greasing three-point bridge DANGER The upper column bearing must be lubricated while the crane is slewed.3 Lubrication of the upper column bearing and three-point bridge The lubrication of the column upper bearing and the three-point bridge is made through nipples placed on the base. 8. If one person lubricates the upper column bearing. Repeat.4.4. • Lubricate. while another is slewing the crane: Take care that the person lubricating the bearing does not come into contact or get crushed by the crane! If you are lubricating the upper column bearing without help: • Lubricate the upper bearing with a little grease.Maintenance and Service 8.3 Front lower slide pads • Extend extensions without load and push slightly against the ground in order to create enough clearance. • Again lubricate with a little grease. 3. viscosity SAE-80W-90. three times.5. Check if the oil level in the level glass ① is between the maximum and minimum levels.Maintenance and Service 8. Refit the plug ③. The slewing housing contains about 13 litres (3. ➀ ➁ 2. 6. Remove the hose coupling ② from the level glass. viscosity SAE-80W90 Changing oil in the slewing housing Change the oil in the slewing house yearly! 1. 4. Operator's Manual GB 93 .5 8. Use a container with sufficient capacity to receive the oil. 3. with transmission oil of type MIL-L-2105C or API-GL-5. Drain off the oil through the filling hose ②. ➂ 2. If the oil level is below the minimum level: Remove the plug ③. If necessary top up again. Top up through the hole for the measuring stick with transmission oil of type MIL-L2105C or API-GL-5. 8. after filling to the end positions. Attach the hose coupling ② to the level glass. Check the oil level. Slew the crane. 7. Refill through the filling hole ③. Remove the plug ③.1 Slewing housing: checking the oil level/oil change Checking the oil level in slewing housing 1.5 Hydraulics 8. 5.43 gallon). 5. Replace the cover ①.5. 2. Remove the cartridge ②. 8. Replacing the cartridge in the high pressure filter (option) is performed likewise. Fit the new filter.5.2 8. Replace if necessary.3 Replacing the cartridge in the pressure reduction filter WARNING Dirt will damage the hydraulic system 1. 94 Operator's Manual GB ➂ ➁ ➀ . 6.5. Fit a new cartridge. Clean the immediate surroundings of the pressure filter. 5. Unscrew and remove the cover ① Unscrew and take out the filter ② Check the condition of the o-rings and gaskets. 3. Also fit a new o-ring ③. Reassemble the filter housing. 1. 4. 3. 2. 4. ➀ ➁ NOTE Check that the cover is properly fitted.2 Replacing the return oil filter Return filter with fouling indicator WARNING Dirt will damage the hydraulic system Make sure that the area around the filter is clean to prevent contamination of the hydraulic oil. Dismantle the filter housing ①. Clean the filter housing.Maintenance and Service 8. 4. 2. 4. Operate the crane for a while to warm the oil. Check the oil level in the tank. ➁ ➂ ➀ 8. 6. 3. WARNING The oil can be hot: up to 80 °C (176 °F). 2. Suitable eye and hand protection must be worn while carrying out this operation. Place the crane in the parked position. 8.5. and if there is a risk for inhalation of oil mist. Remove the cartridge ②. Dismantle the filter housing ①. Also fit a new o-ring ③.5. Clean the immediate surroundings of the pressure filter. If this occurs allow the oil to cool before moving to the next step.6 Changing the hydraulic oil 1.4 High pressure filter [option] WARNING Dirt will damage the hydraulic system Replacing the cartridge in the high pressure filter: 1.5. Fit a new cartridge. Operator's Manual GB 95 . a mask as well. 3. Oil level too low: Top up with hydraulic oil. 2.4 8.5. Reassemble the filter housing. Place the vehicle on level ground.Maintenance and Service 8. Clean the filter housing. 5.5 Checking the oil tank level 1. Place the crane and stabiliser legs in the transport position. Take care that the temperature of the oil does not exceed the point where you can handle it safely. • Eye contact: Rinse eyes with plenty of water. Fill the oil tank with hydraulic oil according to.6 WARNING • Inhalation of oil mist: Contact a doctor. Use a container with sufficient capacity.all filters 5. 3. Change at the same time: . see a doctor if irritation persists.6-62 gallon). ➀ 4. 6. wash with soap and water. Drain the oil tank through the drain plug ①. NOTE Ensure the waste oil is disposed of safely and inaccordance with local environmental regulations. Environmentally Friendly Oil 96 Operator's Manual GB . In the event of high pressure injection of the product. Make sure the system contains as little as possible.5. The capacity of the tank is 40-235 litres (10.Maintenance and Service 8. Refit the drain plug. • Skin contact: Remove polluted clothing. Oil specification for HIAB products Hydraulic oil that is approved for HIAB products must comply with one of the following standards or equivalents: -DIN 51524 part 3 -SS 15 54 34 -ISO 11158 HV Suppliers of hydraulic oil must verify that the quality and performance of the oil complies with the above standards. see a doctor without delay. NOTE Vegetable oils do not meet HIAB’s requirements and must not be used. 8. • Do not mix different oils. or when changing to biodegradadle oil.5. Operate the crane to parking position. mostly for the worse. 9. Under no circumstances must dirt be allowed to enter the oil tank. • When changing from mineral oil to a nonpolluting synthetic oil. Operate each crane function to its end positions.5. In general. To bleed the system see following chapter. NOTE • The oil used for filling must be clean.Maintenance and Service 8. Check and top up the oil tank to max level on the tank gauge.7 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 crane works slowly or jerkily WARNING Air in the hydraulic system can lead to faults and damage To bleed air from the hydraulic system. contact a HIAB service workshop. 7. proceed as follows: Operator's Manual GB 97 .7 The environmentally friendly oils recommended for HIAB products are ester based synthetic hydraulic fluids (synthetic ester) . 8. a mixture will change the properties of the oils. 5 A 7.6.6 Move each crane cylinder and each hydraulically operated piece of add-on equipment at least twice to its end positions (slowly). The indicator light next to On/Off button on the user panel is not lit. • Follow the instructions exactly! • All other faults may be dealt with only by personnel in a HIAB service workshop! 98 Operator's Manual GB 15 A 7. Check all cable connections and close the covers.2 Faults in the HiPro crane Faults in the crane must be rectified immediately. Action Remove the covers and replace the fuses in: • The user panel bottom 2x15A. • The user panel cover 2x7.5 A 3A . DANGER • Only correct yourself the faults that according to the table you may rectify.5A and 3x3A.1 Main fuses If the microprocessor detects a fault. this must be rectified immediately. 15 A 3A 3A 8.6 Troubleshooting 8.6. even if you press On/Off. Probable cause Defective fuses.Maintenance and Service 8. 8. Fault The safety system does not work at all. 2 Fault Probable cause Action Crane does not react to controls. Operator's Manual GB 99 . 2. Make sure that all levers are in neutral. The extensions are still locked. Oil level in the tank is too low. The slewing movements are irregular or cause abnormal noises. Three causes: Warning! Stop using the crane immediately! The stabiliser extensions do not slide out. Clear the blockage or replace the entire filler cap.6. Indicator lamps light up on the user panel. Oil tank filler cap air filter is blocked. The hydraulic pump makes a noise. functions do not work or not properly. Perform movements to reduce load moment. Top up the oil in the slewing housing to the required level. Go to a HIAB service workshop. The upper slewing bearing is not properly lubricated. 1. The pump is faulty. Insufficient oil in the slewing housing. Insufficient oil in the hydraulic system. Top up the oil tank and bleed the hydraulic system. 3. Lubricate the bearing. One remote control function inoperative. If necessary. Crane in an OLP situation. Contact a HIAB service workshop. Push in the stop button. Lifting capacity is much less than normal. Unlock the extensions. Go to a HIAB service workshop. Hydraulic fault. The remote control lever was not in neutral at start up. The bearings in the slewing housing are damaged. Operation speed is significantly reduced. Crane does not work The system has detected a properly: One or more crane fault.Maintenance and Service 8. release OLP. Go to a HIAB service workshop. Check the cables between the DA-modules. The service lamp is lit. Pull out the stop button. Top up the oil tank. Disengage the PTO. Other defect. Error display mode 3. Go to a HIAB service workshop. Use time mode (default) 2. External Display [option] Placing The unit shall be placed under the plastic cover together with the SPACE-box where it is protected from direct water splash. 2. Danger! Keep well away from an oil leak. Press a Stop button. Config mode Use time mode (default) By default the display shows how many hours the crane has been used. hose or line. Contact a HIAB service workshop. Operating modes The display has three basic operating modes: 1. Leak on hydraulic system: leaking coupling. 3.8. Use time is shown on the display as: • • • • 100 USE Number of thousands of hours Number of hours and a dot (Start over) Operator's Manual GB . 1. Reconnect the add-on equipment according to the instructions. Start up The External display automatically starts when the SPACE system is started.2 Maintenance and Service Fault Probable cause Action Add-on equipment does not work properly. Connectors not properly connected.6. (Levers not centred and oil not dumped). Operator's Manual GB 101 . errors can be cleared (as in SPACE terminal) by pressing the button for 2 seconds until the clear errors symbol is shown in the display.Maintenance and Service 8. • Each active error in turn (Blank display if no errors) • (Start over) Press the button again to return to Use time mode.2 example use time=1526 hours Error display mode Press the button to switch to Error display mode. Example: 3 active errors. and then start showing errors as: • The number of active errors and a dot. 003. 014 and 028 Clear errors In Error display mode. Display shows a short time.6. shafts. manufactured from polyamide plastic. bearing bushes. which must be utilized and disposed of correctly. bearings (cleaned of lubricants) used in the column. Most of the crane’s raw materials can be recycled. beam system etc. When the crane is decommissioned at the end of its service life. years from now. directional control valves. control levers. Sort the waste • Deliver the metal parts for recycling. for reuse as raw material. structures manufactured from steel or cast iron. manufactured from polyethene. plastic. waste will be created. 102 Operator's Manual GB . 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. small parts. valves and hoses. These are load-bearing. Energy waste can be utilized by incinerating it at a proper waste incineration plant • spiral wraps.Decommissioning 9 9. The metal parts are designed to achieve a light and durable construction. Environmental requirements and soundness have been considered when selecting the raw materials. hydraulic cylinders and lines drained of oil. The crane must be decommissioned properly. this includes the selection of higherquality grades of steel.1 Decommissioning a crane Cranes are designed and manufactured taking the environment into consideration. Decommissioning 9. Hazardous waste is delivered to a collection point for hazardous waste • oils: hydraulic oil.1 Unsorted waste should be delivered to a landfill • drained hydraulic hoses. transmission oil from the slewing system • solid lubricants: greases from the joints and journal bearings • other waste containing oils and greases: hydraulic oil filters. small plastic and rubber parts. Operator's Manual GB OI L 103 . hydraulic cylinder seals. control cables. lights. seat. electrical wires. 10 Technical Data 10.1 Documentation The Technical Data document shows diagrams and technical information about your specific crane The enclosed Technical Data printed out by the installer should be stored together with this Operator's manual. 104 Operator's Manual GB .