Hiab 335k Operation Maintenance
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Description
Operator's Manual GB HIAB 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.
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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
Table of Contents
5.
6.
4.9
Cranes with high seat [option] ....................................................... 46
4.10
OPS Operator Protection System [option] ........................................ 47
4.11
User panel SPACE 3000 ............................................................... 47 4.11.1 Indicator lights on user panel SPACE 3000 .............................. 48
4.12
User panel SPACE 5000 ............................................................... 49 4.12.1 Indicator lights on user panel SPACE 5000 .............................. 50
4.13
CombiDrive2 .............................................................................. 52
4.14
Main menus CombiDrive2 ............................................................ 55
4.15
Battery charger CD2 .................................................................... 62
4.16
Functions ................................................................................... 63
Starting crane operation ........................................................................ 66 5.1
Starting operations ....................................................................... 66
5.2
Extend stabiliser extensions and set stabiliser legs ............................. 70
5.3
Operate the crane out of parked position .......................................... 72
During operation ................................................................................. 74 6.1
7.
8.
4
OLP (Overload protection) ............................................................ 74
Ending crane operation ......................................................................... 79 7.1
Operate the crane to parking position .............................................. 79
7.4
Placing the stabiliser extensions and legs in transport position ............. 80
7.5
Switching off the safety system ...................................................... 81
7.6
Emergency operation Valve-V91 .................................................... 81
7.7
TWI Transport warning interface [option] ........................................ 82
Maintenance and Service ...................................................................... 84 8.1
Service ...................................................................................... 84
8.2
Warranty .................................................................................... 85
8.3
Follow the maintenance instructions! .............................................. 8.3.1 Daily inspection .................................................................. 8.3.2 Monthly inspection and maintenance ....................................... 8.3.3 Annual maintenance .............................................................
8.4
Lubrication ................................................................................. 90 8.4.1 Lubrication schedule ............................................................ 91 8.4.2 Lubrication of slide pads in boom system ................................ 91 Operator's Manual GB
86 87 88 90
Table of Contents 8.4.3
9.
8.5
Hydraulics .................................................................................. 8.5.1 Slewing housing: checking the oil level/oil change .................... 8.5.2 Replacing the return oil filter ................................................. 8.5.3 Replacing the cartridge in the pressure reduction filter ............... 8.5.4 High pressure filter [option] .................................................. 8.5.5 Checking the oil tank level .................................................... 8.5.6 Changing the hydraulic oil .................................................... 8.5.7 Bleeding air from the hydraulic system....................................
8.6
Troubleshooting .......................................................................... 98 8.6.1 Main fuses.......................................................................... 98 8.6.2 Faults in the HiPro crane ...................................................... 98
93 93 94 94 95 95 95 97
Decommissioning............................................................................... 102 9.1
10.
Lubrication of the upper column bearing and three-point bridge... 92
Decommissioning a crane ............................................................ 102
Technical Data .................................................................................. 104 10.1
Documentation .......................................................................... 104
Operator's Manual GB
5
Knowledge required
1 1.1
This Operator's Manual is intended for operators of this HIAB crane.
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, it could lead to fatal accidents or serious damage. Therefore you should: • Study the entire Operator’s Manual carefully. • Study the operating manuals for other add-on equipment, if fitted. • Use the crane only after having done so. • Follow the directions for use, operation and maintenance of the crane and add on equipment exactly. • Store the Operator’s Manual for your type of crane, the Technical Data and manuals from the Installer, together with this Operator's manual.
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Operator's Manual GB
Knowledge required
1.2
NOTE The manual is written in English and translated to the local language by the manufacturer. The manufacturer reserves the right to change specifications, equipment, operating instructions and maintenance instructions without prior notice.
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. Follow the instructions carefully! WARNING Danger of injury to yourself or to bystanders, or danger of serious damage to the crane or other objects. Follow the instructions carefully.
CAUTION Hazard for the crane or crane components. Follow the instructions carefully. Important: If actions are numbered 1. Do this 2. Do that 3. ...... 4. ..... 5. ..... Operator's Manual GB
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Knowledge required
1.2
you should carry them out in numerical order! NOTE Extra information that can prevent problems. TIP Tip to make the work easier to carry out. Symbol for reference to a component in an illustration. ① Refers to a component in an illustration. [option]: Indication for parts that are not-standard for the crane, but are an option. DANGER Only persons with the requisite knowledge and experience with cranes may use the crane. Never operate the crane when you are sick, tired, under the influence of medicines, alcohol or other drugs. • Take the delivery instructions from your HIAB Service workshop, or receive instruction from an experienced person from your own company. Only then should you operate your crane. • Ensure that you comply with the statutory requirements of the country in which you use the crane (for example, certificate, obligatory safety-helmet).
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Operator's Manual GB
1
Knowledge required
1.2
DANGER • Carry out yourself only the service and maintenance work you have the requisite knowledge and experience of. • All other maintenance work may only be carried out by a HIAB service workshop. • Ensure that every defect is rectified immediately, according to the instructions. • 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, plastic components, signs or bearings with a highpressure jet cleaner. It could cause damage. • Never expose the electronic system to high electrical voltages. This could damage the safety system. • Never immerse the controller in water or other liquid. This will make the controller unusable. If your crane is equipped with add-on lifting equipment (hoist, rotator, etc.): • The operation of the crane with add-on lifting equipment can differ from the operation as described in this manual. • You should therefore study the Operating Manual for the add-on equipment carefully, before you use the crane. • Take particular note when placing the crane in to or out of transport position.
Operator's Manual GB
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Structure and parts of the HIAB crane
2 2.1
Main groups
The HIAB crane consists of the following main groups: • • • •
2.2
Crane base with column and slewing system Boom system Stabiliser system Operating system
Crane base with column and slewing system
The crane base, column and the slewing system consist of the following components: • Crane base with stabiliser beam, column bearings and three-point bridge. • Column this fitted to the crane base and turns in an upper and a lower bearing. • Slewing system
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.
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Operator's Manual GB
1
3
2
Structure and parts of the HIAB crane
2.3
• Add-on lifting accessories [option] Add-on lifting accessories are placed between the boom tip and the load (e.g. pallet fork, grapple, rotator).
Separate lifting accessories [option] Separate lifting accessories, help to make or use a slinging device: eye-hooks, shackles, eye-bolts etc.
Operator's Manual GB
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2.4 2.4
Structure and parts of the HIAB crane Stabiliser system
Every HIAB crane is equiped with two stabiliser extensions and two stabiliser legs. Auxiliary stabiliser systems may be needed for heavy cranes. • Stabiliser beam ①. The stabiliser beam is a part of the crane base. • Stabiliser extensions ②. The stabiliser extensions are hydraulically slid out from the stabiliser beam. • Stabiliser legs ③. Place the stabiliser legs on firm levelled ground to support the crane. • Stabiliser locking device ④. • Support plates ⑤. The support plates are used under the stabiliser legs for additional support.
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Operator's Manual GB
Structure and parts of the HIAB crane 2.5
2.5
Operating system - 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]
• •
2.6
LHV Load holding valves
All cylinders are equipped with load-holding valves as a safety device. After a crane movement they hold the crane in position, also in the unlikely event of a burst hose. If there is a leak or a component fractures, such as a pipe, hose or a coupling, the load-holding valves will stop the booms from collapsing down, even when the hydraulic system is switched off, and you operate a particular crane function. To operate a hydraulic cylinder equiped with a load holding valve, an opening pressure is required.
Operator's Manual GB
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Structure and parts of the HIAB crane
2.7 2.7
Description of Hiab 335K Pro/HiPro-CD
The HIAB 335K are compact, fully hydraulically operated goods cranes. Lifting capacity: • HIAB 335K = 26.6 to 28.9 tonne metres (192 470' 6" ft-lbs to 208 672' 6" ft-lbs) The cranes are supplied in a version: • HIAB 335K-4 reach: 17.3 metres (56' 9" ft) The main control valve V91 and the SPACE 3000 safety system are standard equipment on the HIAB 335K Pro. The main control valve V91, CombiDrive2 and the SPACE 5000 safety system are standard equipment on the HIAB 335K HiPro CD. The crane type and the manufacturer are marked on the serial number plate. NOTE The exact technical information for your crane is shown in the Technical Data.
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Operator's Manual GB
Safety precautions and warnings 3.1
3
Operating conditions
You may only use the crane under the following conditions: • In the open air, or in spaces with sufficient ventilation. • With a mean wind velocity less than 13.3 m/sec (approx. 29.7 mph). See the wind speed table. DANGER • If you use the crane in a confined space you could suffocate from the exhaust gases from the vehicle. • Never use the crane in a high wind or storm. When the mean wind velocity exceeds 13.3 m/sec (approx. 29.7 mph) the crane will behave unpredictably. Never use the crane during a thunderstorm. • Never use the crane at temperatures below -40° C (-40 °F), as the steel's properties deteriorate below this temperature. WARNING • At temperatures below 0 °C (32 °F): Do not touch the operating levers during the first few minutes. • When starting in cold weather, the wear on the hydraulic system is greater than at normal working temperatures. To minimise wear, the crane should be started as follows: • Engage the power take-off at low rpm. • Allow the system to idle for a few minutes. • Fixed pump: Operate the stabiliser leg up for one minute in order to warm up the oil. • Variable pump:
Operator's Manual GB
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Safety precautions and warnings
3.2
Operate stabiliser legs up and down for one minute, in order to warm up the oil.
3.2
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. The cranes are normally mounted on a vehicle but they can also be mounted on a fixed base plate. The crane can be equipped with a number of accessories. Loader cranes are designed for loading and unloading the vehicle, 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, windows...) in building constructions • Lifting construction material (wall boards, bricks, blocks…) on a pallet fork to a building, taking the material from the vehicle on which the crane is mounted, from another vehicle or from the ground • Hoisting, e.g. beams, concrete plates and any other material and equipment used in building construction • With a bucket, moving filling material at a construction site • Handling large loads (containers, boats, machinery, vehicles…) • Collection of waste and recycling material (glass, paper, cardboard, plastic…) • Installation of informative posts, road signs, notice boards, traffic lights, street lights…
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Operator's Manual GB
Safety precautions and warnings
3.2.1
Forbidden duties: • Crane mounted onboard ships or floating structures, only permitted in cases authorized by HIAB • Continuous use as a production crane in assembly lines, foundries…, except for cranes prepared for that purpose • Handle loads, work with submerge boom system or accessories, in strong currents such as rivers • Loading cargo that is partially loaded or fastened by other means, without making sure the capacity of the crane is enough for the entire load • Any duty which implies: • Pressure against the ground, unless the crane is specifically prepared for this • Push/pull with the boom system against any type of obstacle (wall, ground…)
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. 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)
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3.2.2
Safety precautions and warnings
Particular installations can be quieter, in which case a post installation noise measurement in accordance with clause 6.3 of EN 12999:2011 may be used to prove this.
3.2.2 Warning signs XS
XS
LOADER CRANE TYPE SERIAL NO MANUF. YEAR HIAB CRANES S. L. P. Malpica, E, 86 ZARAGOZA - SPAIN
3.2.3 Maximum load Lifting capacity Your crane has a certain lifting capacity, expressed in kNm or tm. This lifting capacity is also known as the load moment. The lifting capacity is: the payload at hook multiplied by the outreach in metres that the crane can operate at different positions. The lifting capacity of your crane determines the maximum load your crane may lift within its working zone. However take careful note; the greater the operating radius of the crane, the lower the lifting capacity will be because of the weight of the boom system itself. The load plate and the load diagram on your crane show the maximum loads you may lift in the operating reach of your crane.
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Operator's Manual GB
Safety precautions and warnings
3.2.3
DANGER • Overloading could result in damage to the crane or in the worst case, personal injury or death. • Never increase a hanging load, since that may cause a load holding valve to open and/or the vehicle to turn over. • Never use the crane with the OLP system switched off. ! NOTE The extra weight of the lifting accessories has to be added to the load. Thus, with lifting accessories the load you can lift is less heavy Load plate You will find the load plate next to the control valve. On the plate is the maximum weight that you may lift at a given reach, with the 1st boom in the optimum position. In chapter Technical Data in this manual you will find these values for your crane. Optimum position The weight that your crane can 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 reach at which you are working and the optimum position of the boom. • The optimal position for your crane is on the load plate. DANGER Never exceed the maximum weight on the load plate.
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3.2.3
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. The load diagram drawing will also be found in the enclosed Technical Data. The white area is the working zone of the crane. The load curves show the maximum load that may be lifted at a given reach and height. For a given maximum load, the possible working zone is to the left of the load curve. The lifting capacity for some cranes is limited in the high lifting area. WARNING Care must be taken when handling loads in the high lifting area, so the load/tool does not come into contact with the boom system.
WARNING Never operate the hydraulic extensions against a solid objet when the first boom is completely lifted. Do not try to push or compress loads when the first boom is fully lifted, as this could cause damage to the first boom cylinder.
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Operator's Manual GB
Safety precautions and warnings
3.2.4
3.2.4 Maximum load moment If your crane has reached the maximum load moment (lifting capacity), the OLP gives a warning and locks any crane movement that will increase the load moment. This is known as an OLP situation. If the second boom is raised, then the following movements are locked: • first boom down/up • second boom down • extension boom out If the second boom is down, then the following movements are locked: • • • •
first boom up second boom up extension boom out first boom down (certain crane types and cases) Lifting the load You obtain the best from your crane in this way: Ensure that you always have the work in clear view. If you cannot see the load properly, you could cause a fatal accident or serious damage.
Operator's Manual GB
21
Safety precautions and warnings
3.2.4
Sling length Always attach the load using the shortest possible sling. The angle between the legs of the sling must not exceed 120°. The maximum working load (usually known as the working load limit (WLL) in standards) of a multilegged sling for general purposes is calculated by multiplying the WLL of a single leg by a mode factor, in accordance with the table. Max angle to the vertical of any sling leg (degrees)
Mode factor two legged sling
Mode factor three and four legged sling
0-45
1,4
2,1
45-60
1,0
1,5
If the angle between the legs of the sling exceeds 90°, the slings should not be hung directly on the hook, but rather be slung from a ring that is hung on the hook. Working close to the load Always try to lift the load with the extension boom retracted, however not completely. The crane then has the greatest lifting capacity. Place the vehicle as close as possible to the load.
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Operator's Manual GB
>1200
Safety precautions and warnings
3.2.4
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.
Heavy loads Lift heavy loads with the second boom in the optimum position in relation to the first boom. For this, see the load plate on your crane. DANGER Never exceed the maximum permissible loading of the hook. Heavy loads cannot be handled with the boom straight. Set the second boom, so there is an angle in relation to the first boom. Loads at the extreme limit of the working zone Also in this case, angle down the second boom somewhat. Only use the first boom . TIP Make smooth crane movements: operate the crane with various functions simultaneously. In this way you will also prevent the hydraulic system heating up quickly.
Operator's Manual GB
23
Safety precautions and warnings
3.3 3.3
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. • The country-specific regulations for crane operator signals are to be used. Signals in this manual give a number of standard signals that can be used. Lift Raised arm and index finger raised. Circular motion with hand.
Lower Arm pointing downwards and index finger down. Circular motion with hand.
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Operator's Manual GB
Safety precautions and warnings
3.3
Stop all crane movements Also: Hold the load in position. Raise the open hand, with the palm clearly visible, and arm at shoulder height. Keep the hand still.
Emergency stop for all movements by the crane. Raise the hands and the arms to an oblique angle.
Very short movement Place the hands a very short distance apart, with the palms facing each other. The hands may be held either horizontally or vertically. The next movement may be: Lift, lower, move the lifting gear, change the reach, or turn.
Change the reach Signal with your hands. • Sideways movement outwards with both hands. Thumbs outwards. • Sideways movement inwards with both hands. Thumbs inwards.
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3.3
Safety precautions and warnings
Turn in the direction indicated Indicate the direction with the hands.
Open the grapple Extend the arms at shoulder height, with the palms facing downwards.
Close the grapple Move both hands close together.
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Operator's Manual GB
Safety precautions and warnings
3.3
Lift the open grapple a little Extend both arms at shoulder height, with the palms facing upwards. Make vertical movements with both arms outstretched.
Keep the grapple in position briefly Raise the hand drooping slightly, with the fist clenched.
Operator's Manual GB
27
Safety precautions and warnings
3.4 3.4
Wind speeds
Wind speed averaged over 10 minutes at a height of 10 m Above flat ground
Wind Force
m/s
0
0.0 - 0.2
1 2
0.3 - 1.5 1.6 - 3.3
3 4
3.4 - 5.4 5.5 - 7.9
5
8.0 - 10.7
28
Characteristics
Wind type Calm
Calm, smoke rises vertically or nearly vertically
Slight breeze
Wind direction recognisable from smoke plumes, the wind begins to be noticeable on the face; leaves begin to rustle and weather vanes can start to move.
Moderate wind
Leaves and twigs in continuous movement, small branches begin to move. Dust and paper begin to move over the ground.
Fairly strong wind Small leaved branches make swaying movements; crested waves form on lakes and canals. Strong wind
Large branches move; you can hear the wind whistling in telephone wires; umbrellas can only be held with difficulty.
6
10.8 - 13.8
7
13.9 - 17.1
Severe wind
Entire trees move; the wind causes difficulty when you walk into it.
8
17.2 - 20.7
Stormy wind
Twigs break off, walking is difficult.
Storm 9
20.8 - 24.4
Causes superficial damage to buildings (chimney pots, roof-tiles, and TV antennae are blown off).
Severe storm 10
24.5 - 28.4
Uprooted trees; considerable damage to buildings etc. (occurs infrequently on land).
11
28.5 - 32.6
Very severe storm
Causes extensive damage (occurs very infre quently on land).
12
> 32.6
Hurricane
Operator's Manual GB
Safety precautions and warnings 3.5
3.5
Use of the crane
Starting crane operation DANGER • Ensure you can see the stabiliser legs and stabiliser extensions when you are operating them. • Do not stand in front of the hydraulically operated stabiliser legs when you are operating them! • Where the ground is not firm enough, use support plates under the stabiliser legs for additional support. Use support plates that are large and firm enough for your crane. Check that the support plate as, it comes under load, is not pushed into the ground. Check that the support plate does not bend under load. • Do not lower the stabiliser legs on the edge of an embankment, soft shoulder, slope etc. Lower the stabiliser legs only on to a flat surface. • Slide the stabiliser extension, on both sides of the vehicle, out completely if possible. Then lower the stabiliser legs for support. • Never operate the stabiliser legs, while the crane has a load! • Never unfold the crane from the position shown. WARNING • Use low force when placing the stabiliser legs on the ground. • Do not raise the vehicle with the stabiliser legs, if the crane is equiped with only two stabiliser legs! If you raise the vehicle with the stabiliser legs, this may damage the stabiliser legs. Operator's Manual GB
29
Safety precautions and warnings
3.5 Preparations for use DANGER
Ensure that there are no unauthorised persons within the operating range of your crane!
TIP Mark out the working range, e.g. with cones. Put on your vehicle's warning lights.
DANGER • If a part of the crane comes in contact with an electricity line, you will be electrocuted! • Maintain the following minimum distances between the crane and overhead electricity lines, unless otherwise prescribed by national rules. Minimum distance between crane and over head electricity lines Voltage (V)
Minimum distance to an insulated conductor
Minimum distance to an uninsulated conductor
40000 V
2.0 m
6m
Voltages are found: up to 500 V:
to buildings
500-40000 V:
trams, trains
over 40000V:
power transmisson
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Operator's Manual GB
Safety precautions and warnings
3.5
DANGER • Wear a safety helmet (compulsory in some countries!). • Check that the ground is sufficiently flat. Use chocks under the wheels on a gentle slope. • Check that the ground is sufficiently firm. • Also, check that the ground is not undermined. Look out for sewers, cellars, excavations etc. The stabiliser legs must not be able to sink in! • On a slippery surface, for example because of frost: Place chocks under the wheels. • Activate the vehicle parking brake! Otherwise, the vehicle can start to move during lifting. • Never use the stabiliser legs as a parking brake, since the vehicle could start to slide. • Check that the add-on lifting accessories and separate lifting accessories are in good order! Add-on lifting accessories are sometimes fitted on the crane (hoist, JIB) or placed between the boom tip and the load (grapple, rotator). Separate lifting accessories are connected to the standard load hook (slings, chains, chackles etc). Crane operation DANGER Your crane has a safety system. The safety system will help you to work safely. Nevertheless, you remain responsible for safe use of the crane! Therefore, always work according to the operating instructions!
Operator's Manual GB
31
Safety precautions and warnings
3.5
In an emergency immediately switch off all crane movements! • Press a stop button. To avoid unexpected load movements and at every interruption in crane operation. • 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, have someone else give you signals. See the list of signals. Make certain that you and the person assisting you know these signals. • Pay attention to the safety of the person giving the signals! • Never move the vehicle, if you have a freely-suspended load on the crane! • Never walk or stand under a suspended load! During operation, never stand below the boom system or load! • Do not slew the crane, nor lift the first boom, nor lift the second boom into their ends positions at full speed. This can damage the crane.
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Operator's Manual GB
Safety precautions and warnings
3.5
WARNING • Never push a load along the ground, or the vehicle's load space, with the extension boom. This can cause damage to the boom system. This will lead to expensive repairs. • Never use the extension boom as a jack. This could damage the slewing bearings and the connection between the crane column and the crane base. • Always lift the load from the ground before you start to slew. Do not tow the load over the ground. This can damage the boom system. • If you are working with loads in restricted spaces (for example, windows): Check that the boom system can move up and down freely. The boom system will bend somewhat, when loading and unloading the crane. • If the boom system is in a high position (first boom above 70°), do not allow the boom to lower at full speed. The crane could go into an uncontrolled movement. Be careful if, in particular, the OLP gives an early warning! • When loading the vehicle: Take the load off the stabiliser legs by withdrawing them slightly. The stabiliser legs must remain in light contact with the ground.
CAUTION • Operate the crane using smooth and gentle lever movements. • If a cylinder is at its end position, free the operating lever. Otherwise overheating can occur.
Operator's Manual GB
33
Safety precautions and warnings
3.5
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. The PTO or power supply must be disengaged. The operating system must be switched off! • Pay attention to the width and height of the crane in the transport position. The crane has to stay within the width of the truck. Make sure the stowed crane can not hit bridges, tunnels etc. • Pay attention to overhead power lines! Make sure that no part of the crane ever comes in contact with overhead power lines. For further instructions see vehicle's manual(s).
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Operator's Manual GB
Safety precautions and warnings
3.5
Ending crane operation DANGER Always end crane operation as follows: • After use, always place the crane in the transport position! • When you have to park the boom on the load space, or over the load; secure the boom and the lifting accessories to prevent any movement of the crane and the lifting accessories. • Withdraw the stabiliser legs and stabiliser extensions. • Lock tiltable stabiliser legs and manual operated stabiliser extensions in transport position. • Check that the locking mechanisms are properly locked. • Switch off the operating system. • Disengage the PTO or power supply after work. • If you drive with the PTO or power supply engaged, this will cause serious damage to the PTO/gearbox combination. • Only after doing the above, should you drive the vehicle away.
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35
Safety precautions and warnings
3.6 3.6
Use of lifting equipment DANGER
• Only use lifting accessories that are suitable for your crane. Contact a HIAB service workshop. • Never attempt to install add-on lifting accessories yourself! • Add-on lifting accessories may only be installed by an authorised HIAB service workshop. • When using lifting accessories, 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. Check that the lifting accessories are securely fixed. 2. Only after this should you use your crane. WARNING • Clean the couplings, when connecting and disconnecting lifting accessories. Dirt can damage the hydraulic system. • Take care that your fingers are not trapped
3.7
Use of dismountable cranes DANGER
• Ensure that there are no unauthorized persons in the immediate vicinity of the crane. 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
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
The Safety system
4 4.1
Safety System SPACE 3000/5000 and Remote Control
SPACE 3000 and 5000 are different versions of a crane safety system. With the remote control CombiDrive2 you can control the crane remotely. The safety system: • Monitors the crane's operation and prevents unsafe actions. • Increases the precision with which you can work. • Makes operation easier. • Makes troubleshooting easier. SPACE 3000 is used on cranes with manual control. The control valve is type V91. SPACE 5000 is used on cranes with control valve type V91 and remote control CombiDrive2. Crane version
Control Valve
Safety system
Pro
V91
SPACE 3000
HiPro
V91
SPACE 5000
NOTE The safety system provides a large number of functions. Certain functions are standard, others are options. If you do not use the system for 30 minutes, it will switch itself off, in order to prevent draining the truck battery. This feature can be cancelled. Contact your HIAB Service workshop.
4.2
How the safety system works
The safety system works as follows:
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Operator's Manual GB
The Safety system
4.2
On the crane there are various sensors and indicators which send signals about the crane’s load, position and movements to a central microprocessor. The microprocessor then decides how the crane can be operated and stops/reduces prohibited movements/speeds according to the following: • When prohibited movements/speeds are approached, a warning is given. • When prohibited movements/speeds are reached: On remote controlled cranes prohibited movements are stopped. On manually operated cranes, all movements are stopped, because when a spool is moved too much, power to the dump valve is cut, all movements are stopped. Fault monitoring When there is a fault in the safety system it will give an immediate warning. Depending upon the fault the crane speed and/or the load capacity will be reduced. When the fault is serious, use of the crane is blocked completely. DANGER Never try to repair the safety system yourself. Repairs may only be made by a HIAB service workshop!
Operator's Manual GB
39
The Safety system
4.3 4.3
Components of SPACE Safety System
Main control valve ① • The crane can be operated from the main control valve, but as soon as you have selected remote control operation, it is impossible to operate the main control valve levers. User interface - Microprocessor ② • This is the user interface for SPACE 3000 (Pro cranes) or SPACE 5000 (HiPro cranes). Here is where the operator turns on and off the system and activating stabiliser legs and OLP release. Activating the remote control and the signal horn. There is also an emergency stop button on the user interface. Filter ③ • Pressure reduction filter. The filter feeds the positioners with filtered oil. Dump valve 1 ④ • To prevent high pressure and thereby unnecessary heating of the oil there is an automatic dumping function. When no lever movement has been made for 3 seconds SPACE system opens the dump valve and the oil is returned directly to the hydraulic tank. As soon as the operator moves a lever the valve closes. Dump valve 2 • Allows operation of the stabiliser extensions and legs only when this valve is activated. The dump valve 2 will be placed between the main control valve and the stabiliser control valve. The dump valve 2 must be activated from the SPACE interface before the stabiliser system can be controlled. Decoder ⑤
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Operator's Manual GB
➈ ➂ ➃
➁ ➆
➀ ➈ ➄ ➅
➇
The Safety system
4.3
Remote controller CombiDrive2 (HiPro cranes) ⑥ • The controller is the device that the operator use to control the crane. 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. Lamp pole ⑧ [option] • The lamp pole is equipped with 3 lamps. Flashing/light up: green, 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, by amber light indication. A warning lamp also gives information to the operator about the different statuses of 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
The Safety system
4.4 4.4 • • • • • • • •
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, regardless of the load and other functions, as long as the oil flow is sufficient. When the oil flow is insufficient, one or more functions might reduce their speed. When remote control is used, the oil flow is allocated by means of PFD.
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Operator's Manual GB
The Safety system
4.5
Main control valve lever function
Operator's Manual GB
43
4.6 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.
1
3
➁ ➀
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Operator's Manual GB
The Safety system 4.7
4.7
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.
4.8
Selector valve [option]
Use lever ① to select:
➃
➂ ➁
➀
➀
• Crane functions: manual or remote • Stabiliser system functions
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45
The Safety system
4.9 4.9
Cranes with high seat [option]
The high seat is equipped for using tools and operated by two joystick levers: ① and ②; and two foot pedals: ③ and ④. 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, it is necessary to sit down on the seat to operate the controls. DANGER Take care not to put your foot on the pedals when taking place in the high seat. Unintentional crane movements can occur. Hydraulic stabiliser extensions and legs are controlled by an additional control valve fitted to the stabiliser beam.
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Operator's Manual GB
1
3
4
2
The Safety system
4.10
4.10 OPS Operator Protection System [option] • OPS is a system that protects the operator from the boom system's movements when operating the crane. The OPS system is integrated in the SPACE system, and it uses a sensor on the rack and tilt indicators on the boom system, to indicate the position of the crane. It creates a virtual cage around the area where the crane operator stands, while manually operating the crane.
4.11 User panel SPACE 3000 Manually controlled cranes are equipped with user panel SPACE 3000 Functions: • Stop button ① When you push the stop button, all crane movements are stopped immediately. • ON/OFF button ② to switch the safety system On/Off. • Button ③ Push the button to operate stabiliser extensions and legs. The button is also an OLP release button with the functions: Disconnecting the automatic dump function. OLP release. • Button ④, to sound the horn, if present. • Button ⑤ Push the button, to switch the manual extensions on/off.
SPACE 3000
➁ ➂
Operator's Manual GB
➀ ➃ ➄
47
The Safety system
4.11.1
4.11.1 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. Green light flashing: An emergency stop button is depressed or remote control selected.
Service
②
Green light on: Time to service the crane. Red light on: A non-critical error detected in the system. Red light flashing: Critical error is stopping the crane. Diagnostic required. Red light dubble flash: CAN Error, crane stops.
OLP Release
③
Red light on: OLP (crane, VSL [option] or stabiliser leg [option]) Red light blinking: OLP Release (crane, 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).
Stabiliser leg/extension [option]
⑤
Automatic duty control
⑥
Hoist LED
48
➂
Green light on: Dump 1 active.
Green light on: Stabiliser extensions fully out and legs set to ground. Lamp blinking: Stabiliser extension is not fully out. Stabiliser leg set to ground. Red light on: Stabiliser leg overload. Green light on: Increased capacity (ADC mode).
⑦ Not active.
Operator's Manual GB
The Safety system
4.12
Cylinder pressure LED's
⑧
Manual extension
⑨ Not active.
Slewing sector [option]
⑩
Green light on: Outside slewing sector, normal capacity. Light off: Inside slewing sector, reduced capacity. Red light on: OLP. Vehicle has reached a stability limit. (Also all the 1st boom diodes will light red).
VSL: Variable Stability Limitation [option]
⑩
Green light on: Full VSL stability. Light off: Vehicle has limited stability but, crane capacity is not fully used. Red light on: VSL OLP. Vehicle has reached a stability limit. (Also all the 1st boom diodes will light red).
Green light A on: 50% of OLP pressure. Green light A - B on: 70% of OLP pressure. Red light A - C flashes: 90% of OLP pressure. Red light A - D on: 100% of OLP pressure. Red light blinking from A to D: OLP Release.
Lamp test for the user panel SPACE 3000 See: Daily inspection.
4.12 User panel SPACE 5000 Cranes with remote control, type CombiDrive2 and control valve type V91 are equipped with user panel SPACE 5000: Functions: • Stop button ① When you push the stop button, all crane movements are stopped immediately. • ON/OFF button ② with the symbol to switch the safety system On/Off. • Button ③ with the symbol To switch on the remote control and radio control.
➁ ➂ ➀
➃
➄
• Button ④ with the symbol To select manual function. • Confirm view button ⑤ with the symbol Operator's Manual GB
49
The Safety system
4.12.1
To confirm full view of operating the stabiliser extensions outward.
4.12.1 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. Green light flashing: An emergency stop button is depressed.
Service
②
Green light on: Time to service the crane. Red light on: A non-critical error detected in the system. Red light flashing: Critical error is stopping the crane. Diagnostic required. Red double flash: CAN error, crane stops.
OLP Release
③
Red light on: OLP. Red light blinking: OLP release button has been pressed. 5 sec to release OLP.
Slewing sector [option]
④
Light off: Inside slewing sector, reduced capacity. Red light on: OLP. Vehicle has reached a stability limit. (Also all the 1st boom diodes will light red).
VSL: Variable Stability Limitation [option]
④
Green light on: Full VSL stability. Light off : Vehicle has limited stability but, crane capacity is not fully used. Red light on: VSL OLP. Vehicle has reached a stability limit. (Also all the 1st boom diodes will light red).
Automatic duty control
⑥
Green light on: Increased capacity (ADC mode)
Hoist LED
⑦ Not active.
Operator's Manual GB
The Safety system
4.12.1
Cylinder pressure LED's
⑧
Remote control
⑨
Manual extensions
⑩ Not active.
Manual control
⑪
Green light on: Manual control.
Stabiliser system
⑪ ⑫
Green light on: The stabiliser system is ready to use.
Green light A on: 50% of OLP pressure. Green light A-B on: 70% of OLP pressure. Red light A-C flashes: 90% of OLP pressure. Red light A-D on: 100% of OLP pressure. Red light blinking from A-D: OLP release. Green light on: Remote control. Good radio connection. Green light blinking: Stop button pressed/no radio. connection. Red light blinking: Radio interference.
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4.13
The Safety system
4.13 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. This means that information can be sent both from and to the controller. In the decoder/radio there is a corresponding unit which handles the traffic at the other end. The radio is of the “Bluetooth” type and therefore operates in the 2.4 GHz band. 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, including across national boundaries. The controller is equipped with a menu selection system as standard. The display continuously provides the operator with information. The centre display provides information about which menu has been chosen, as well as indicating the radio reception conditions, battery status, fault information, micro, ADC, manual extension, and so on. The side displays show the symbol for the function which each lever activates in the chosen menu. When the operator changes menu, the symbols change to the functions that become active. Via cable: A four-metre cable is supplied as standard with the radio kit of 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. The cable connects to the vehicle at the left-hand CAN bus connector on the decoder. 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. To give the operator greater freedom of movement, a 15-metre cable is used between the adapter and the controller. 52
Operator's Manual GB
The Safety system When the cable is connected to the controller, the centre display indicates that the controller is in cable operation mode. The symbols for signal strength (radio) and battery capacity are replaced with the symbol for cable operation. Low ambient temperature
4.13
CRANE 1
CRANE 1
The LCD-type displays on the controller are somewhat slow in changing state under low temperature conditions. At 0°C, it will take approximately 1 s, and at -20°C it can take up to 8 s before the symbols are completely changed. Alternating symbols will not be updated at temperatures below freezing. In order to prevent accidental menu shifts in cold weather, below -10°C, there will be a time delay before any menu button will react to a second depression. In order to avoid this inconvenience, HIAB recommends that whenever the controller is not in use, it should be stored in a compartment where the temperature exceeds +10°C. Centre display Centre display
View modes
The centre display as it appears when the controller is started.
Main menu This text shows which main menu that has been selected. The number shows the relevant sub-menu of that main menu. The main menus are CRANE, EXTRA and ON-OFF. Signal strength The bars show the radio signal strength. Five bars indicate optimum reception conditions. If the symbol flashes, the radio is connected but the starting conditions are not met. Battery capacity The battery symbol shows remaining energy in the battery. When the symbol begins to flash there is capacity for just a few more minutes. When this happens the horn on the crane will beep twice as an indication of low battery. This information is intended for the Safety System, which could give an acoustic signal to emphasize the warning and make the operator aware.
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4.13
The Safety system
Centre display
View modes
Error This symbol, a spanner, appears if the Safety System, has discovered a fault in the system.
ADC Indicates that the ADC function is active.
Micro Indicates that micro operation has been selected. Microoperation changes the resolution of the levers as follows: At full lever deflection, μ50% is 50% of normal speed and µ20% is 20% of normal speed.
Manual extension If manual extension is used, this information must be sent to Safety System. Safety System, acknowledges by showing this symbol.
Micro / adc / manual extension indication When one of the above functions is activated or engaged, the symbol is enlarged for three seconds. It then returns to its normal size. This is to show the operator that a change has happened. Fault indication- Not critical If a fault is detected in the control or Safety System, the fault symbol a spanner appears. When the symbol appears, it is enlarged for three seconds in the upper part of the centre display. Fault indication- Critical The fault symbol spanner appears enlarged and becomes large. The crane stops. Error code display The Safety System, has the possibility to send error codes to the controller. By pressing the info-button, the centre display changes state to show the error codes. The error codes scroll up on the centre display at the same rate as the Safety System, sends them. If there are more than six error codes at the same time, the six most recent ones sent from the Safety System, are shown.
Alternating symbols will not be updated at temperatures below freezing.
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Operator's Manual GB
ADC
Enlarged
Normal size
The Safety system
4.14
Info-Button Use this button for changing the centre display window.
4.14 Main menus CombiDrive2 There are two versions of CombiDrive2, with six or eight levers. 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. 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, e.g. 1-2-3 and then back to 1 again. The restriction is that one function is only present on a specific lever. If a lever is faulty, or if it is deflected on startup, it is disabled. The other levers operate in the usual way. With the 2 extra levers on the 8 lever controller, it it possible to use the seventh and eighth functions simultaneously with functions 1-6, without shifting main CRANE menu.
Operator's Manual GB
➁ ➂
3
2
1
55
4.14
The Safety system
Menu: CRANE CRANE menu button When the operator pulls out the stop button on the controller, it always starts in CRANE 1 menu. The submenus in “CRANE” mode are configured in production but can be changed by HIAB service personnel. For every lever there is a corresponding function which it controls. This appears in the left or right display. When the menu changes, by pressing the CRANE menu button, the symbols change and the functions are activated in the current menu. The symbols are stored in a symbol library and can be configured/set via the terminal program for a CE crane. Symbols for the 8 lever controller: Left side display
Centre display
"CRA NE MENU " 3
2
1
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Operator's Manual GB
➀
Right side display
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
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The Safety system
4.14 Menu: EXTRA
EXTRA menu button This button activates the EXTRA menu. The “EXTRA” main menu contains hydraulically proportional functions for example front and rear stabiliser extensions and legs, boat supports, bunk shifting, etc. These display symbols must match the function being used. The function is logically positioned in relation to the lever. The symbols are configured in the same way as for the “CRANE” main menu. The same method is used for stepping between the sub-menus. Left is defined as the side of the crane where the main control valve is normally placed. The order of the levers is customized. For the 6 lever controller: If the crane has 1 stabiliser control valve, the order of the levers should be:
EXTRA 2
1
2
3 4
Lever
58
Functions, lever forward, 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 Safety system
4.14
If the crane has 2 stabiliser control valves, the order of the levers should be: Menu 2: Lever
Functions, lever forward, 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, 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, the order of the levers should be: 1
Lever
2
3
4
5
6
7
8
Functions, 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
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4.14
The Safety system
If the crane has 2 stabiliser control valves, the order of the levers should be: Lever
60
Functions, lever forward, 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
The Safety system
4.14
Menu: ON-OFF ON-OFF menu button This button enables the on-off functions. The “On-off” main menu includes functions such as start, stop and throttle. The functions are configured by the bodybuilder. Currently there are no symbols for these functions. Instead, text can be entered directly into the window that corresponds to each function. Only ordinary numerals and the letters of the English alphabet can be used. For each sub-menu, four functions may be defined. The functions are controlled by levers 2 – 5. A lever may be deflected in any direction in order to activate the corresponding function. "ON-OFF MENU"
Left side display
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 Safety system
4.15
4.15 Battery charger CD2 The battery charger is to be fitted in a protected environment, preferably in the cab. Two batteries are delivered with each unit, one of which can always be placed in the charger. Display A ① lights when the charger is activated. ① and ② lights during charging. ① and ③ lights when the battery is fully charged. Display B Shows the battery voltage (8.4). When the display blinks 0.0 there is error in the battery: Change battery. Charging time The normal charging time for an flat battery, is approximately 3 hours. The battery charger is designed not to damage the battery, even during long continuous charging. Operating ambient temp: Battery = 0° to + 45°C. A charged battery The voltage level of a fully charged battery is approximately 8,4V and it provides about 5-8 hours working time. Note that the battery voltage remains between 7,6V and 7,5V for a long time. Therefore, the battery voltage cannot be used to estimate the working time. NOTE A charged battery is a concentrated energy source. Never store a charged battery in a toolbox or similar, where there is a risk of a short due to metal components. Used batteries should be taken care of according to the local regulations.
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Operator's Manual GB
➀
A
➀ ➁
➀ B
➂
The Safety system
4.16
Installing the battery Install a fully-charged battery in the controller as shown on the right. It is important to fit the battery the right way round. If the battery is upside-down the controller will not start. A fully charged 1200 mAh battery will power the controller for approximately 5 hours.
4.16 Functions Locking / unlocking the controller The controller can be locked to prevent unauthorised persons, such as children, from starting the controller and operating the crane. Locking the controller • Press buttons “EXTRA” and “ON/OFF” while the stop button is pressed. • Keep the buttons pressed while pulling out the stop button. 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. Keep the buttons pressed while pulling out the stop button. Release the buttons. The controller is ready to use. ADO Automatic dump function If a lever is not moved for 3 seconds, this function diverts the oil to the tank, thereby preventing the oil from overheating. The next lever movement stops the dumping and it functions as normal. Disconnecting the automatic dump function (ADO) In certain cases the automatic dump function must be disconnected. The most common case is before operating a separate stabiliser control valve (which is not equipped with spool sensors) Operator's Manual GB
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4.16
The Safety system
To disconnect the automatic dump function: 1. Press the Button ①. The LED ② is lit constantly when automatic dump function is disconnected. 2. Press the Button ① again. The automatic dump function is now connected again. When the power is switched on, the automatic dump function is always connected. ASC Automatic Speed Control
➀
The ASC function automatically provides the extra power by reducing the speed smoothly, when working close to the rated capacity. When the load decreases, normal speed is restored. ADC Automatic Duty Control The purpose of the ADC function is to increase the lifting capacity by 10%. The first boom pressure sensors indicate if there is a positive or negative pressure on the first boom. Normal capacity • If the first boom is pressed down, the sensors indicate a negative pressure and the lifting capacity is normal during the complete lifting cycle. Increased capacity (ADC mode) • ADC lamps light up. If the sensors indicate a positive pressure, the lifting capacity is increased during the complete lifting cycle. PFD Pump flow distribution When operating several functions simultaneously the pump flow may not be sufficient. PFD will now take over, reducing the speed of all operated functions. Uncontrolled movements are thus avoided, smooth simultaneous operation is achieved.
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Operator's Manual GB
ADC
➁
The Safety system
4.16
Controlling crane speed Use the micro button to change resolution of the lever to 50% or 20% of normal speed.
Slewing sector [option] Within slewing sector, lifting capacity can be reduced due to stability. The overload warning will be given at a lower load in the limited sector than outside the sector. In case of an overload warning you may slew out of the sector but not further into it. VSL Variable Stability Limitation [option] The VSL function senses the outreach and the attachment of the stabiliser legs to the ground, and automatically calculates the level of OLP limit. This means that the crane always works with the highest possible lifting capacity in relation to the stability.
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Starting crane operation
5 5.1
Starting operations
Placing the vehicle • General case: Place the vehicle on a flat surface. The vehicle inclination (α) during crane operation must not be more than allowed in the Technical Data for your crane. To determine the inclination of the truck, check the spirit level on the crane. When the bubble is in the middle of the gauge, the crane is in horizontal position. When the bubble is between the two circles, the crane inclination is between 0° and 5°. If the slope exceeds the permitted inclination, unintentional crane movements can occur.
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, the vehicle has to be completely levelled in any direction. NOTE • Operating the crane in to and out of parking position must also be done with the vehicle completely levelled.
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Operator's Manual GB
60°
60°
Starting crane operation
5.1
Engage the PTO • Engage the PTO (Power Take Off). • Bring the vehicle's engine to the correct rpm. NOTE • Rpm too high: the oil in the hydraulic system might overheat. Rpm too low: during crane operation, the vehicle's engine could stall. • The maximum rpm may depend upon a governor on your PTO combination. CD2 Start the safety system The operating levers must be in neutral position before start up. To activate the system, press the On/Off button on the user panel. The LED above the button starts to blink. The system will check itself (2-4 seconds)
The warning lamps [option] on the stabiliser legs light up.
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5.1
Starting crane operation
Remote control CD2 1. Fasten the contoller to a waist belt, or shoulder-/neck strap, in the most comfortable operation position. The Stop button should be on the right hand side. 2. Press the remote control button on the user panel. The diode above that button gives a steady light.The green lamp on the lamp pole [option] lights.
3. To activate the controller, pull out the stop button by turning it clockwise. The radio starts to establish a link with the decoder. “Wait” is displayed while radio contact is being established.
Decoder LED’s colour: ① green ② yellow ③ red The decoder is powered on when remote control is chosen. LED ① is lit. The LED ② on the decoder starts to blink. Radio link established
➂ ➁ ➀
• When the radio link has been established, LED ② on the decoder gives a steady light and LED ① flickers. • On the controller, CRANE 1 menu and signal strength are displayed. 68
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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.
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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.
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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
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Starting crane operation
5.3 5.3
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. Once the stabiliser extensions and legs are ready you can start using the crane: 1. If stabiliser system is under manual control, push the remote button on the user panel. 2. If using remote controller, push button CRANE MENU on the controller to change the menu into crane operation.
➀
DANGER Always operate manually controlled crane from the position indicated !
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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.
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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.
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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.
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6.1
During operation
OLP Stabiliser system [option] If a stabiliser leg is overloaded, slewing is stopped in the direction towards the stabiliser leg where the OLP occurs. The VSL indicator lamp light red on the user panel. The crane stops. 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 display symbol goes back to normal.
100% CRANE 1
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EXTRA 2
During operation
6.1
VSL - OLP [option] VSL-OLP occurs when there is a risk of instability of the vehicle. The slewing is stopped towards the instability direction and the crane stops. The centre display indicates VSL. The VSL indicator lamp light red on the user panel. The 100% symbol in the left display alternates with OLP for crane. Move all the levers to neutral and operate permitted (load reducing) functions only. The display symbol goes back to normal.
VSL CRANE 1
100%
To release OLP (CombiDrive2) In certain OLP situations, the first and second booms can be locked. It is then possible to release the OLP for approximately 5 seconds, by pressing the release-button on the right hand side below the display handle. There is a waiting time before the release operation can be activated again. The time increase in three steps: 30, 60 and maximum 90 seconds (the time starts to count down as you move the lever). During this period it is possible to operate an appropriate crane function so as to correct the overload situation. Only one unallowed function at a time can be operated. Extension out cannot be operated. The unlocked padlock will appear in the centre display.
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During operation
6.1
On the user panel the cylinder pressure LED’s and the lamp for padlock symbol will flash red. Manual control If one prohibited movement is used, all movements will stop. The crane will be fully operational as long as only allowed movements are used. DANGER Only use the OLP override to get the crane out of a locked position. Never use the OLP override to overload the crane deliberately!
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Ending crane operation 7.1
7
Operate the crane to parking position WARNING
• A crane with add-on equipment can differ from the operations described in this section. • For this reason, study the operating instructions for any add-on equipment carefully. During folding, always operate the crane manually from the position indicated in the figure. 1.
Slew the crane until the crane is parallel to the vehicle. 2. Retract the extensions completely. 3. Lower the boom system against the vehicle. (Do not extend the second boom cylinder fully). 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.
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Ending crane operation
7.4 If selector valve [option]:
If the crane has selector valve move lever ① to stabiliser system position.
7.4
Placing the stabiliser extensions and legs in transport position
Activate operation of stabiliser extensions and legs. DANGER Do not stand in the stabiliser legs, tilting area.
DANGER Always ensure that the stabiliser legs and the stabiliser extensions are in transport position and securely locked.
WARNING Do not put your foot on the support plate. Operation with non-tiltable stabiliser legs 1. 2. 3. 4.
80
If loose support plate delivered, rectract a little the stabiliser leg, if not, go to step 3. Unlock the loose support plate. Retract the stabiliser leg. Retract the stabiliser extension completely.
Operator's Manual GB
➀
Ending crane operation
7.5
The catcher ① will lock the stabiliser extension. Repeat for the stabiliser extension and leg on the other side of the vehicle
5.
When there is an additional set of stabiliser legs [option]: Repeat the process for the 3rd and 4th stabiliser legs.
7.5
Switching off the safety system ➀
• Push in the stop button and switch off the safety system. • Disengage the PTO.
7.6
Emergency operation Valve-V91
EMERGENCY operation to bring the crane to parking position Do like this: On the main control valve: 1. Break the security sealing on dump valve 1 on the inlet section. 2. Press the dump valve button and turn 90 degrees until it is blocked. 3. Operate the crane to parking position using the levers on the main control valve.
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Ending crane operation
7.7
Separate stabiliser control valve: The button on dump valve 1 on the main control valve is to remain depressed. 1. Break the security sealing on dump valve 2. The dump valve 2 is placed on the main control valve, on the outlet section. 2. Press the dump valve button and turn 90 degrees until it is blocked. 3. Operate the stabiliser extensions and stabiliser legs to parking position using the levers on the stabiliser control valve. DANGER To operate the crane like this is HIGHLY DANGEROUS because during emergency operation all crane security is disconnected. Always go to/contact a HIAB service workshop when the seal wire has been broken.
7.7
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, and/or if the first boom angle exceeds a certain specified angle, the indicator lamps for both the cylinders and the hoist will flash red for a while. The vehicle must not be moved.
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Ending crane operation
7.7
• A warning, visible and audible from the driving position for transport, 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. • The audible warning can be silenced by an acknowledgement button [option] or by a signal indicating that the parking brake of the vehicle is engaged. The vehicle must not be moved 1. Switch the system on, put the crane into the transport position. 2. Switch off the system. The vehicle may be moved. DANGER After use always put the crane into the transport position! When you have to park the boom on the load space, or over the load, secure the boom and the lifting accessories to prevent any unintentional movement of the crane and the lifting accessories.
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Maintenance and Service
8 8.1
Service DANGER
• Do not do any welding work on the crane yourself! Welding work on the crane may only be carried out by, or in close consultation with, a HIAB service workshop. • Do not drill into the crane yourself. Drilling work on the crane may only be carried out by, or in close consultation with, a HIAB service workshop. • Never try to reinstall the crane.Only a HIAB Dealer may reinstall the crane. Before carrying out any welding on the vehicle 1. Switch off the operating system. 2. Disconnect the MINUS cable. 3. Disconnect the PLUS cable. 4. Place the earth connection as close as possible to the welding spot. 5. After this, the welding work can be carried out After welding on the vehicle 1. Connect the PLUS cable. 2. Connect the MINUS cable.
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Maintenance and Service
8.2
Leakage DANGER • Keep well away from an oil leak on the hydraulic system! The oil spraying out can cause serious injury. The oil in the hydraulic system is under high pressure. • 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. Pressure may be retained in the hydraulic lines when the power supply has been switched off. • Always contact a HIAB service workshop. Deal with an oil leak as follows: 1. Rest the crane on the floor or on the truck platform. 2. Switch off the operating system. 3. Disengage the PTO. 4. Leaking coupling: Tighten the coupling with a spanner. If tightening does not help: contact a HIAB service workshop. 5. Small leak on a a line or hose: Determine if you can still fold the crane. If you can: fold the crane and go to a HIAB service workshop. If you cannot: contact a HIAB service workshop. 6. In all other cases, contact a HIAB service workshop.
8.2
Warranty
HIAB only provides a warranty if: • The instructions for maintenance and service have been followed, and original HIAB parts have been used. Operator's Manual GB
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Maintenance and Service
8.3
• All seals on the valves are still intact. Always use original HIAB parts and tools.
8.3
Follow the maintenance instructions!
Take the crane, at least once a year, to a HIAB service workshop for inspection and maintenance. Maintain lifting accessories according to the supplier’s instructions. WARNING • Ensure that faults in the crane are corrected immediately! • Never correct faults yourself that may only be corrected by a HIAB service workshop. • Carry out yourself only the service and maintenance work you have the requisite knowledge and experience of. If the crane is not be used for 1 month or longer: • Lubricate the crane thoroughly, according to the lubrication schedule. • Park the crane in the transport position. Filters Replace the filter cartridge • after the first 50 hours operation • then after every 500 hours operation • or at least twice a year. Cleaning Clean your crane and accessories regularly, but: • Do not use aggressive cleaning agents. • Never use a high pressure jet cleaner on electronic parts, plastic components, signs, bearings, control valves, cylinders or the oil tank. Only the cranes surface may be cleaned with a high-pressure jet cleaner. 86
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Maintenance and Service
8.3.1
8.3.1 Daily inspection Stabiliser locking devices • Check that the stabiliser locking devices are undamaged and working properly. Shafts, shaft lockings, bearings and bushings • Check that the shafts, shaft lockings, bearings and bushings are undamaged and working properly. Stop buttons • Check that the Stop buttons are undamaged and working properly. Hook, hook lock and hook suspension • Check that these are in good condition. Levers • Check that the levers operate smoothly. • Check that the levers return to the neutral position. Electronic components • Check that these are in good condition. Crane structure • Check for damage to the crane structure (e.g. any formation of cracks). DANGER In the event of damage that presents a safety risk: • Do not use the crane. • Have the damage repaired immediately by a HIAB service workshop. Hydraulic system • Check that there are no leaks from the hydraulic hoses, lines and connections. Filters • Check the filter indicator. If red replace the cartridge. Operator's Manual GB
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8.3.2
Maintenance and Service
LED test To do the test: 1. Press the ON/OFF button for at least 2 sec. The test is activated and all the red LED's are illuminated. If the system is equipped with lamp pole, all three lamps will light. 2. Release the button. After 3 sec, all the green the LED's are illuminated. The test is finished when all LED's is extinguished. Add-on equipment • Maintain all add-on equipment, auxiliary equipment etc. according to the instructions supplied with it. Oil tank level • To check the level in the oil tank: Place the vehicle on level ground with the crane in transport position. • If necessary, top up. Slewing housing oil level • Check the oil level in the slewing housing. • If necessary, top up.
8.3.2 Monthly inspection and maintenance In addition to the daily inspection, carry out the following each month. Piston rods • In cases where the cylinder piston rod is exposed to pollution due to the parking location, the chromed surfaces must be cleaned and oiled to prevent corrosion. This needs to be done regularly.
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Maintenance and Service
8.3.2
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. • Check that all other notices and stickers are in position: load plates, loading diagram, warning symbols. Pivot pins and bushes • Inspect all the pivot pins and bushes for the crane boom and cylinders for damage, play, etc. Bolts and screw fixings • Check that bolt and screw fixings are tightened. Hydraulic pump fixing • Check the hydraulic pump attachment underneath the vehicle. Cables and sensors on the boom system • Check that these are in good condition. Lubrication schedule • Carry out the lubrication according to the instructions. Hydraulic system oil • Check if the oil in the hydraulic system should be changed. • Or have the oil tested by a workshop or specialist. Add-on equipment etc. • Maintain all add-on equipment, auxiliary equipment etc. according to the instructions supplied with it.
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Maintenance and Service
8.3.3
8.3.3 Annual maintenance Take the crane, at least once a year, to a HIAB service workshop for inspection and maintenance. Carry out the following maintenance at least once a year. Hydraulic oil • Change the hydraulic oil. Or have it tested by a workshop or specialist. Oil in the slewing housing • Change the oil in the slewing housing Hydraulic system oil tank filler cap • Change the filler cap. • Replace filters.
8.4
Lubrication WARNING
Follow the lubrication schedule exactly. If you not do so, there may be serious damage to the crane and to add-on equipment. Type of grease Use lithium based grease containing EP additives (consistencies 2 and 3 are recommended, depending on the climate). Recommended greases: BP LS EP 2, ESSO UNIWAY EP2 N, AGIP GR MU/EP3, NYNÄS UNIFETT EP. NOTE Avoid grease with graphite or molybdenumdisulphide additives.
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Maintenance and Service
8.4.1
8.4.1 Lubrication schedule Lubricate after every 16 hours of use. Lubricate after every 50 hours of use. A: Internal pads B: Internal guides See chapter of Slewing housing Lubrication
A
B
B
8.4.2 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. • Retract the extensions. Front upper slide pads • Extend extensions with load in order to create enough clearance. • Lubricate. Operator's Manual GB
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Maintenance and Service
8.4.3 Front lower slide pads
• Extend extensions without load and push slightly against the ground in order to create enough clearance. • Lubricate.
8.4.3 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. 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. If one person lubricates the upper column bearing, 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. • Slew the crane a little. • Again lubricate with a little grease. Repeat, until the column has been slewed round completely.
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➀ ➁
Maintenance and Service 8.5
8.5
Hydraulics
8.5.1 Slewing housing: checking the oil level/oil change Checking the oil level in slewing housing 1. Check if the oil level in the level glass ① is between the maximum and minimum levels.
➂
2. If the oil level is below the minimum level: Remove the plug ③. 3. Top up through the hole for the measuring stick with transmission oil of type MIL-L2105C or API-GL-5, viscosity SAE-80W90 Changing oil in the slewing housing Change the oil in the slewing house yearly! 1. Remove the hose coupling ② from the level glass.
➀
➁
2. Remove the plug ③. 3. The slewing housing contains about 13 litres (3.43 gallon). Use a container with sufficient capacity to receive the oil. Drain off the oil through the filling hose ②. 4. Attach the hose coupling ② to the level glass. 5. Refill through the filling hole ③, with transmission oil of type MIL-L-2105C or API-GL-5, viscosity SAE-80W-90. 6. Refit the plug ③. 7. Slew the crane, after filling to the end positions, three times. 8. Check the oil level. If necessary top up again.
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Maintenance and Service
8.5.2
8.5.2 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. 1. 2. 3. 4. 5.
Unscrew and remove the cover ① Unscrew and take out the filter ② Check the condition of the o-rings and gaskets. Replace if necessary. Fit the new filter. Replace the cover ①.
➀
➁
NOTE Check that the cover is properly fitted.
8.5.3 Replacing the cartridge in the pressure reduction filter WARNING Dirt will damage the hydraulic system 1.
Clean the immediate surroundings of the pressure filter. 2. Dismantle the filter housing ①. 3. Remove the cartridge ②. 4. Clean the filter housing. 5. Fit a new cartridge. Also fit a new o-ring ③. 6. Reassemble the filter housing. Replacing the cartridge in the high pressure filter (option) is performed likewise.
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➂ ➁
➀
Maintenance and Service
8.5.4
8.5.4 High pressure filter [option] WARNING Dirt will damage the hydraulic system Replacing the cartridge in the high pressure filter: 1. 2. 3. 4. 5. 6.
Clean the immediate surroundings of the pressure filter. Dismantle the filter housing ①. Remove the cartridge ②. Clean the filter housing. Fit a new cartridge. Also fit a new o-ring ③. Reassemble the filter housing.
➁ ➂ ➀
8.5.5 Checking the oil tank level 1. 2. 3. 4.
Place the crane and stabiliser legs in the transport position. Place the vehicle on level ground. Check the oil level in the tank. Oil level too low: Top up with hydraulic oil.
8.5.6 Changing the hydraulic oil 1. Operate the crane for a while to warm the oil. Place the crane in the parked position. Take care that the temperature of the oil does not exceed the point where you can handle it safely. If this occurs allow the oil to cool before moving to the next step. WARNING 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, and if there is a risk for inhalation of oil mist, a mask as well.
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Maintenance and Service
8.5.6 WARNING
• Inhalation of oil mist: Contact a doctor. • Skin contact: Remove polluted clothing, wash with soap and water. In the event of high pressure injection of the product, see a doctor without delay. • Eye contact: Rinse eyes with plenty of water, see a doctor if irritation persists. 3. Drain the oil tank through the drain plug ①. Make sure the system contains as little as possible. The capacity of the tank is 40-235 litres (10.6-62 gallon). Use a container with sufficient capacity. NOTE Ensure the waste oil is disposed of safely and inaccordance with local environmental regulations.
➀
4. Change at the same time: - all filters 5. Refit the drain plug. 6. Fill the oil tank with hydraulic oil according to. 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. Environmentally Friendly Oil
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Maintenance and Service
8.5.7
The environmentally friendly oils recommended for HIAB products are ester based synthetic hydraulic fluids (synthetic ester) . NOTE Vegetable oils do not meet HIAB’s requirements and must not be used. 7. Operate each crane function to its end positions. Operate the crane to parking position. 8. Check and top up the oil tank to max level on the tank gauge. 9. To bleed the system see following chapter. NOTE • The oil used for filling must be clean. Under no circumstances must dirt be allowed to enter the oil tank. • When changing from mineral oil to a nonpolluting synthetic oil, or when changing to biodegradadle oil, contact a HIAB service workshop. • Do not mix different oils. In general, a mixture will change the properties of the oils, mostly for the worse.
8.5.7 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, proceed as follows: Operator's Manual GB
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Maintenance and Service
8.6
Move each crane cylinder and each hydraulically operated piece of add-on equipment at least twice to its end positions (slowly).
8.6
Troubleshooting
8.6.1 Main fuses If the microprocessor detects a fault, this must be rectified immediately. Fault The safety system does not work at all. The indicator light next to On/Off button on the user panel is not lit, even if you press On/Off. Probable cause Defective fuses. Action Remove the covers and replace the fuses in: • The user panel bottom 2x15A. • The user panel cover 2x7,5A and 3x3A. Check all cable connections and close the covers.
15 A
3A 3A
8.6.2 Faults in the HiPro crane Faults in the crane must be rectified immediately. DANGER • Only correct yourself the faults that according to the table you may rectify. • Follow the instructions exactly! • All other faults may be dealt with only by personnel in a HIAB service workshop!
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15 A
7,5 A 7,5 A
3A
Maintenance and Service
8.6.2
Fault
Probable cause
Action
Crane does not react to controls. Indicator lamps light up on the user panel.
Crane in an OLP situation.
Perform movements to reduce load moment. If necessary, release OLP.
Crane does not work The system has detected a properly: One or more crane fault. functions do not work or not properly. Lifting capacity is much less than normal. Operation speed is significantly reduced. The service lamp is lit.
Contact a HIAB service workshop.
One remote control function inoperative.
The remote control lever was not in neutral at start up.
1. Push in the stop button.
2. Make sure that all levers are in neutral.
3. Pull out the stop button. Check the cables between the DA-modules. The hydraulic pump makes a noise. Three causes: Warning! Stop using the crane immediately!
The stabiliser extensions do not slide out.
The slewing movements are irregular or cause abnormal noises.
Oil tank filler cap air filter is blocked.
Clear the blockage or replace the entire filler cap.
Oil level in the tank is too low.
Top up the oil tank and bleed the hydraulic system.
The pump is faulty.
Go to a HIAB service workshop.
The extensions are still locked.
Unlock the extensions.
Hydraulic fault.
Go to a HIAB service workshop.
Insufficient oil in the hydraulic system.
Top up the oil tank.
Insufficient oil in the slewing housing.
Top up the oil in the slewing housing to the required level.
The upper slewing bearing is not properly lubricated.
Lubricate the bearing.
The bearings in the slewing housing are damaged.
Go to a HIAB service workshop.
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8.6.2
Maintenance and Service
Fault
Probable cause
Action
Add-on equipment does not work properly.
Connectors not properly connected.
Reconnect the add-on equipment according to the instructions.
Other defect.
Go to a HIAB service workshop.
Leak on hydraulic system: leaking coupling, hose or line. Danger! Keep well away from an oil leak.
1. Press a Stop button. 2. Disengage the PTO. 3. Contact a HIAB service workshop.
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. Start up The External display automatically starts when the SPACE system is started.
Operating modes The display has three basic operating modes: 1. Use time mode (default) 2. Error display mode 3. Config mode Use time mode (default) By default the display shows how many hours the crane has been used. (Levers not centred and oil not dumped). 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
Maintenance and Service
8.6.2
example use time=1526 hours Error display mode Press the button to switch to Error display mode. Display shows a short time, and then start showing errors as: • The number of active errors and a dot. • Each active error in turn (Blank display if no errors) • (Start over) Press the button again to return to Use time mode. Example: 3 active errors, 003, 014 and 028 Clear errors In Error display mode, errors can be cleared (as in SPACE terminal) by pressing the button for 2 seconds until the clear errors symbol is shown in the display.
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Decommissioning
9 9.1
Decommissioning a crane
Cranes are designed and manufactured taking the environment into consideration. Environmental requirements and soundness have been considered when selecting the raw materials. The metal parts are designed to achieve a light and durable construction, this includes the selection of higherquality grades of steel. When the crane is decommissioned at the end of its service life, years from now, waste will be created, which must be utilized and disposed of correctly. The crane must be decommissioned properly. Most of the crane’s raw materials can be recycled. Follow the regulations of the local authorities! • Oil and grease must not be spilled on to the ground or released into the environment! • Drain the oil from hydraulic cylinders, valves and hoses.
Sort the waste • Deliver the metal parts for recycling, for reuse as raw material. These are load-bearing, structures manufactured from steel or cast iron, hydraulic cylinders and lines drained of oil, directional control valves, shafts, bearing bushes, control levers, small parts.
Energy waste can be utilized by incinerating it at a proper waste incineration plant • spiral wraps, manufactured from polyethene, plastic, bearings (cleaned of lubricants) used in the column, beam system etc, manufactured from polyamide plastic.
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Decommissioning
9.1
Unsorted waste should be delivered to a landfill • drained hydraulic hoses, electrical wires, control cables, seat, hydraulic cylinder seals, lights, small plastic and rubber parts.
Hazardous waste is delivered to a collection point for hazardous waste • oils: hydraulic oil, transmission oil from the slewing system • solid lubricants: greases from the joints and journal bearings • other waste containing oils and greases: hydraulic oil filters.
Operator's Manual GB
OI
L
103
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
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