Hiab 335k Operation Maintenance

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.
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 Operators 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

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.
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
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
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 Operators
Manual for your crane carefully, it could lead
to fatal accidents or serious damage.
Therefore you should:
Study the entire Operators 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 Operators Manual for your type of
crane, the Technical Data and manuals from
the Installer, together with this Operator's
manual.
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 Operators

Manual
What must you do and not do?

The following indications are used in the Operators 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. .....
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.
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).
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.
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
2nd boom
Hydraulic extensions
The extensions are operated by hydraulic
cylinders placed inside the extensions.
10
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.
11
2.4
2.4

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 . The stabiliser beam is a
part of the crane base.
Stabiliser extensions . The stabiliser extensions are hydraulically slid out from the
stabiliser beam.
Stabiliser legs . Place the stabiliser legs on
firm levelled ground to support the crane.
Stabiliser locking device .
Support plates . The support plates are used
under the stabiliser legs for additional support.
12

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.
13
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.
14

3.1
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:
15
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
16
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)
17
3.2.2
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.
18
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.
19
3.2.3
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.
20
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.
21
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.
22
>1200
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.
23
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.
24
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.
25
3.3
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.
26
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.
27
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 - 0.2
1
2
0.3 - 1.5
1.6 - 3.3
3
4
3.4 - 5.4
5.5 - 7.9
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.
10.8 - 13.8
13.9 - 17.1
Severe wind
Entire trees move; the wind causes

difficulty when you walk into it.
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

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.
29
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
<500 V
0.5 m
2m
500-40000 V
1.5 m
4m
>40000 V
2.0 m
6m
Voltages are found:

up to 500 V:
to buildings
500-40000 V:
trams, trains
over 40000V:
power transmisson
30
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!
31
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.
32
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.
33
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).
34
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.
35
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
3.7
WARNING
Take care when mounting/dismounting the
crane on/off the vehicle.
Roughly handling can seriously damage the
crane or the vehicle.
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:
38
The Safety system
4.2
On the crane there are various sensors and

indicators which send signals about the cranes
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!
39
The Safety system
4.3
4.3
Components of SPACE Safety

System
Main control valve

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
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
Pressure reduction filter. The filter feeds the
positioners with filtered oil.
Dump valve 1
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
40
The Safety system
4.3
Remote controller CombiDrive2 (HiPro

cranes)
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 [not applies]
Select the oil flow towards either the crane or
the stabiliser system.
Lamp pole [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 [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
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.
42
The Safety system
4.5
Main control valve lever function
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:
Stabiliser leg
upward/downward
Stabiliser extension
out/in
The stop button affects the oil supply to this
valve.
44
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:
Stabiliser leg
upward/downward
Stabiliser extension
out/in
Extra stabiliser leg
upward/downward
Extra stabiliser extension
out/in
The stop button affects the oil supply to this
valve.
4.8
Selector valve [option]
Use lever to select:
Crane functions: manual or remote

Stabiliser system functions
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: and ; and
two foot pedals: and . The control valve is
placed at the high seat.
The controls have the functions:
Joystick
First boom: downward/upward
Add-on equipment
Joystick
Second boom: downward/upward
Add-on equipment
Pedal
Extension boom: out/in
Pedal
Slew: clockwise/counterclockwise
For safety reasons, it is necessary to sit down on
the seat to operate the controls.
DANGER
Take care not to put your foot on the pedals
when taking place in the high seat. Unintentional crane movements can occur.
Hydraulic stabiliser extensions and legs are controlled by an additional control valve fitted to the
stabiliser beam.
46
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
When you push the stop button, all crane
movements are stopped immediately.
ON/OFF button to switch the safety
system On/Off.
Button
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 , to sound the horn, if present.
Button
Push the button, to switch the manual extensions on/off.
SPACE 3000
47
The Safety system
4.11.1
4.11.1 Indicator lights on user panel

SPACE 3000
D
D A BC
C
B
SPACE 3000
Power On
Green light on: The system is on.

Green light flashing: An emergency stop button is
depressed or remote control selected.
Service
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
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
OLP Release
Green light on both : Stabiliser functions are activated

(dump 1 and 2 active).
Stabiliser
leg/extension
[option]
Automatic duty
control
Hoist LED
48
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).
Not active.
The Safety system
4.12
Cylinder
pressure LED's
Manual
extension
Not active.
Slewing sector
[option]
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]
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
When you push the stop button, all crane
movements are stopped immediately.
ON/OFF button with the symbol to
switch the safety system On/Off.
Button with the symbol
To switch on the remote control and radio
control.
Button with the symbol

To select manual function.
Confirm view button with the symbol
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
50
11
A BC
D
C
B
A
AB
CD
12
Power On
Green light on: The system is on.

Green light flashing: An emergency stop button is
depressed.
Service
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
Red light on: OLP.

Red light blinking: OLP release button has been
pressed. 5 sec to release OLP.
Slewing sector
[option]
Light off: Inside slewing sector, reduced capacity.

Red light on: OLP. Vehicle has reached a stability
VSL: Variable
Stability
Limitation
[option]
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
Automatic duty
control
Green light on:

Increased capacity (ADC mode)
Hoist LED
Not active.
The Safety system
4.12.1
Cylinder
pressure LED's
Remote control
Manual
extensions
Not active.
Manual control
Green light on: Manual control.
Stabiliser system
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.
51
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
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 0C, it will take
approximately 1 s, and at -20C 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 -10C, 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 +10C.
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.
53
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, 50% is 50% of
normal speed and 20% 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.
54
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
EXTRA menu button
ON-OFF menu button
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.
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
56
Right side display
The Safety system
4.14
Symbols for the 6 lever controller:

Left side display
Centre
display
Right side display
"CRANE MENU"
57
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
3
4
Lever
58
Functions, lever forward, on the

controller
Left stabiliser extension out
Left stabiliser leg down
Right stabiliser extension out
Right stabiliser leg down
5
6
The Safety system
4.14
If the crane has 2 stabiliser control valves, the

Menu 2:
Lever

controller
Left crane stabiliser extension out
Left crane stabiliser leg down
Left auxiliary stabiliser extension out
Left auxiliary stabiliser leg down
Menu 3:
Lever

controller
Right crane stabiliser extension out
Right crane stabiliser leg down
Right auxiliary stabiliser extension out
Right auxiliary stabiliser leg down
For the 8 lever controller:

If the crane has 1 stabiliser control valve, the
1
Lever

controller
Left stabiliser extension out
Left stabiliser leg down
Right stabiliser extension out
Right stabiliser leg down
59
4.14
The Safety system
If the crane has 2 stabiliser control valves, the

Lever
60

controller
Left auxiliary stabiliser extension down
Left auxiliary stabiliser leg out
Left crane stabiliser extension down
Left crane stabiliser leg out
Right crane stabiliser extension out
Right crane stabiliser leg down
Right auxiliary stabiliser extension out
Right auxiliary stabiliser leg down
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
Centre
display
FRONT
LIGHT
REAR
LIGHT
ON-OFF 2
ENGINE
START
ENGIN
E STOP
ON-OFF 1
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
lights when the charger is activated.
and lights during charging.
and 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 + 45C.
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.
62
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)
63
4.16
The Safety system
To disconnect the automatic dump function:

1. Press the Button .
The LED is lit constantly when automatic dump function is disconnected.
2. Press the Button 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
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.
64
ADC
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.
65
5
5.1
Starting operations
Placing the vehicle

General case:
Place the vehicle on a flat surface. The vehicle
inclination () 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
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 60, 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.
66
60
60
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.
67
5.1
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 LEDs colour:

green
yellow
red
The decoder is powered on when remote control
is chosen. LED is lit. The LED on the
decoder starts to blink.
Radio link established
When the radio link has been established,

LED on the decoder gives a steady light
and LED flickers.
On the controller, CRANE 1 menu and signal
strength are displayed.
68
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.
69
5.2
If selector valve [option]:
If the crane has selector valve move lever to

stabiliser system position.
5.2
Extend stabiliser extensions and

set stabiliser legs
To ensure the full crane capacity, all the stabiliser

extensions and legs must be fully extended and
set to the ground.
NOTE
The stabiliser leg's downward movement is automatically stopped at a given force level. To
exceed this force level, operate the stabiliser leg
down once again.
WARNING
Take care not to lower the stabiliser leg to
your foot.
DANGER
Check that the support plates do not bend or
sink into the ground!
WARNING
Always ensure that the stabiliser legs and
stabiliser extensions are in working position
and securely locked.
70
5.2
Operation with non-tiltable stabiliser legs:

Unlock the catcher .
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.
71
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.
DANGER
Always operate manually controlled crane
from the position indicated !
72
5.3

crane position.
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.
73
During operation
6
6.1
OLP (Overload protection)
OLP HiPro crane

The OLP function is a safety function in SPACE
that prevents overloading of the crane.
With 90% of maximum permitted load, a prewarning is given.
The warning lamp [option] on the stabiliser leg
double blink and the cylinder pressure LED's
flash red.
The yellow lamp on the lamp pole [option]
flashes and the cylinder pressure LED's flash red.
When 100% of the maximum permitted pressure

is reached, the OLP cuts in. The display shows
whether a particular motion is prohibited or if the
crane is subject to OLP. The warning lamp
[option] on the stabiliser leg will flash twice , the
red and the amber lamps on the lamp pole
[option] will light all the time and the cylinder
pressure LED's will light continuously.
74
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 are flashing on the user
panel when load is close to rated capacity and
light up at rated capacity.
75
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
76
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.
77
During operation
6.1
On the user panel the cylinder pressure LEDs

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!
78

7.1
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.
79
7.4

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.
7.5
The catcher 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
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.
81
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.
82
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.
83
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.
84
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.
85
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
suppliers 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
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
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.
87
8.3.2
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.
88
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
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.
89
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, NYNS UNIFETT EP.
NOTE
Avoid grease with graphite or molybdenumdisulphide additives.
90
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
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.
91
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 : For greasing upper column bearing
Niple : 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.
92

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 is
between the maximum and minimum levels.
2. If the oil level is below the minimum level:

Remove the plug .
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 from the
level glass.
2. Remove the plug .

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 .
4. Attach the hose coupling to the level
glass.
5. Refill through the filling hole , with
transmission oil of type MIL-L-2105C or
API-GL-5, viscosity SAE-80W-90.
6. Refit the plug .
7. Slew the crane, after filling to the end
positions, three times.
8. Check the oil level. If necessary top up
again.
93
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

Unscrew and take out the filter
Check the condition of the o-rings and
gaskets. Replace if necessary.
Fit the new filter.
Replace the cover .
NOTE
Check that the cover is properly fitted.
8.5.3 Replacing the cartridge in the

pressure reduction filter
WARNING
1.
Clean the immediate surroundings of the

pressure filter.
2. Dismantle the filter housing .
3. Remove the cartridge .
4. Clean the filter housing.
5. Fit a new cartridge. Also fit a new o-ring .
6. Reassemble the filter housing.
Replacing the cartridge in the high pressure filter
(option) is performed likewise.
94
8.5.4
8.5.4 High pressure filter [option]

WARNING
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 .
Remove the cartridge .
Clean the filter housing.
Fit a new cartridge. Also fit a new o-ring .
Reassemble the filter housing.
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.
95
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
. 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.
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
96
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 HIABs 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:
97
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!
98
15 A
7,5 A 7,5 A
3A
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.
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.
workshop.
99
8.6.2
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.
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)
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.
101
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 cranes
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.
102
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.
OI
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

Hiab 335k Operation Maintenance

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Hiab 335k Operation Maintenance

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Operator's Manual GB

HIAB 335K Pro-HiPro CD

Congratulations with your new crane!

Knowledge required ............................................................................... 6

Indications in the Operators Manual ................................................ 7

Structure and parts of the HIAB crane ..................................................... 10

Main groups ............................................................................... 10

Crane base with column and slewing system .................................... 10

Boom system .............................................................................. 10

Stabiliser system .......................................................................... 12

Operating system - hydraulic components ........................................ 13

LHV Load holding valves ............................................................. 13

Description of Hiab 335K Pro/HiPro-CD ......................................... 14

Safety precautions and warnings............................................................. 15

Operating conditions .................................................................... 15

Signals when using a crane............................................................ 24

Wind speeds ............................................................................... 28

Use of the crane .......................................................................... 29

Use of lifting equipment ............................................................... 36

Use of dismountable cranes ........................................................... 36

The Safety system................................................................................ 38

Safety System SPACE 3000/5000 and Remote Control ...................... 38

How the safety system works......................................................... 38

Components of SPACE Safety System ............................................ 40

Operating components .................................................................. 42

Main control valve ....................................................................... 42

Stabiliser control valve ................................................................. 44

Extra stabiliser leg [option] ........................................................... 45

Selector valve [option].................................................................. 45

Cranes with high seat [option] ....................................................... 46

OPS Operator Protection System [option] ........................................ 47

User panel SPACE 3000 ............................................................... 47

User panel SPACE 5000 ............................................................... 49

Main menus CombiDrive2 ............................................................ 55

Battery charger CD2 .................................................................... 62

Starting crane operation ........................................................................ 66

Starting operations ....................................................................... 66

Extend stabiliser extensions and set stabiliser legs ............................. 70

Operate the crane out of parked position .......................................... 72

During operation ................................................................................. 74

OLP (Overload protection) ............................................................ 74

Ending crane operation ......................................................................... 79

Operate the crane to parking position .............................................. 79

Placing the stabiliser extensions and legs in transport position ............. 80

Switching off the safety system ...................................................... 81

Emergency operation Valve-V91 .................................................... 81

TWI Transport warning interface [option] ........................................ 82

Maintenance and Service ...................................................................... 84

Follow the maintenance instructions! ..............................................

Lubrication of the upper column bearing and three-point bridge... 92

Decommissioning a crane ............................................................ 102

Technical Data .................................................................................. 104

Documentation .......................................................................... 104

This Operator's Manual is

This manual describes:

Indications in the Operators

What must you do and not do?

you should carry them out in numerical order!

Structure and parts of the HIAB crane

The HIAB crane consists of the following main

Crane base with column and slewing system

Crane base with column and

The boom system consists of the following

Structure and parts of the HIAB crane