HIAB X-Duo 044 Manuel utilisateur

This operator’s manual is an Original Instruction and applies to cranes with serial

number from:

BL044DO00001, BL078DU00001, BL088DO00001, BL102DU00001,

BL112DU00001

2018-01

Operator's Manual GB

HIAB X-Duo

044/078/088/102/112

2Operator's Manual GB

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, control 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.

Help us to improve this manual. Please send your

comments and suggestions to [email protected]

This manual includes interactive contents.

Download the 'Hiab AR+ App' for the interactive content in this manual. Look for the

AR+symbol. Use your device to scan the image next to the symbol.

The interactive contents in the Hiab AR+ App will display suggestions to make the crane

operation easier for you to understand. However, note that some of the content included in

the 'Hiab AR+ App' may differ from the actual configuration of your crane and is subject

to updates and changes from Hiab without prior notice.

Table of Contents

Operator's Manual GB

1. Introduction.......................................................................................... 7

1.1 This Operator's Manual is intended for operators of this HIAB crane. .... 7

1.2 Cleanliness certificate .................................................................... 8

1.3 Indications in the Operator’s Manual ................................................ 8

2. Structure and parts of the HIAB crane..................................................... 12

2.1 Main groups ............................................................................... 12

2.2 Crane base with column and slewing system .................................... 12

2.3 Stabiliser system.......................................................................... 13

2.4 Boom system .............................................................................. 14

2.5 Accessories on the boom system .................................................... 15

2.6 Operating system - hydraulic components ........................................ 17

2.7 LHV Load holding valves ............................................................. 18

2.8 Description of HIAB X-Duo.......................................................... 18

3. Safety precautions and warnings............................................................. 19

3.1 Operating conditions .................................................................... 19

3.2 Wind speeds ............................................................................... 20

3.3 Definition of a HIAB loader crane.................................................. 21

3.3.1 Determination - Hoist........................................................... 23

3.3.2 Noise declaration................................................................. 23

3.3.3 Signs on the crane ............................................................... 24

3.3.4 Maximum load [AR+] .......................................................... 24

3.3.5 Maximum load moment........................................................ 26

3.4 Signals when using a crane [AR+].................................................. 29

3.5 Use of the crane .......................................................................... 32

3.5.1 Preparations for use ............................................................. 34

3.5.2 Crane operation................................................................... 35

3.5.3 Service platform [option] ...................................................... 37

3.5.4 Driving with the crane.......................................................... 38

3.5.5 Use of the Hoist .................................................................. 38

3.5.6 Use of lifting equipment ....................................................... 39

3.5.7 Use of demountable cranes.................................................... 40

3.5.8 Ending crane operation ......................................................... 41

4. The Duo system .................................................................................. 42

Table of Contents

Operator's Manual GB

4.1 The Duo system .......................................................................... 42

4.2 How the safety system works......................................................... 42

4.3 Components of the Duo system...................................................... 44

4.4 Standard symbols and functions of the crane and the stabiliser system .. 45

4.5 Main control valve....................................................................... 47

4.6 Different stabiliser control valves ................................................... 47

4.7 User panel.................................................................................. 48

4.7.1 Indicator LEDs on user panel................................................. 48

4.8 Control platform [option] .............................................................. 50

4.9 High seat [option]........................................................................ 50

5. Starting crane operation ........................................................................ 52

5.1 Starting operations [AR+] ............................................................. 52

5.2 Set the stabiliser system................................................................ 53

5.2.2 Activate the stabiliser system................................................. 55

5.2.3 Extend the stabiliser extensions [AR+] .................................... 56

5.2.4 Set the stabiliser legs [AR+] .................................................. 57

5.3 Operate the boom system out of transport position ............................ 60

5.3.1 BDA Boom Deployment Assistance [option] [AR+] .................. 61

6. During operation ................................................................................. 63

6.1 Functions ................................................................................... 63

6.1.1 OPS Operator Protection System [option] ................................ 63

6.1.2 APO Automatic power off..................................................... 63

6.1.3 ADO Automatic dump function ............................................. 64

6.1.5 Slewing sector [option]......................................................... 64

6.2 OLP (Overload protection) ............................................................ 64

6.2.1 OLP (Overload protection) .................................................... 64

6.2.2 To release OLP ................................................................... 65

6.2.3 OLP release on user panel..................................................... 66

6.3 Manual extensions [option] ........................................................... 66

6.4 Change from hoist to hook operation .............................................. 69

7. Ending crane operation ......................................................................... 73

7.1 Operate the boom system into transport position ............................... 73

7.1.1 Operate the boom system ...................................................... 73

Table of Contents

Operator's Manual GB

7.2 Placing the stabiliser system in the transport position [AR+] ............... 75

7.2.5 Retract the stabiliser extensions [AR+].................................... 78

7.3 Switching off the control system .................................................... 79

7.4 Emergency operation Valve-V30.................................................... 79

7.5 Emergency operation Valve-V80.................................................... 80

7.6 TWI Transport warning interface.................................................... 82

8. Maintenance and Service ...................................................................... 83

8.1 Service ...................................................................................... 83

8.2 Warranty.................................................................................... 84

8.3 Follow the maintenance instructions! .............................................. 85

8.3.1 Daily inspection .................................................................. 86

8.3.2 Monthly inspection and maintenance....................................... 89

8.3.3 Annual maintenance............................................................. 91

8.3.4 Hoist maintenance ............................................................... 91

8.3.5 Check rope ......................................................................... 93

8.3.6 Cleaning the rope ................................................................ 93

8.3.7 Course and requirements of the rope ....................................... 94

8.3.8 Change of rope.................................................................... 95

8.3.9 Maintenance and monitoring of rope end ................................. 97

8.4 Lubrication................................................................................. 97

8.4.1 Lubrication schedule ............................................................ 98

8.4.2 Lubrication of the upper column bearing ................................. 99

8.4.3 Lubrication of the column bearings......................................... 99

8.4.4 Lubrication of the hooks ..................................................... 100

8.5 Hydraulics ................................................................................ 101

8.5.1 Slewing housing: checking the oil level/oil change .................. 101

8.5.2 Checking the oil tank level .................................................. 101

8.5.3 Changing the hydraulic oil................................................... 102

8.5.4 Bleeding air from the hydraulic system.................................. 105

8.5.5 Replacement of filters......................................................... 105

8.5.6 Replacing the cartridge in high pressure filter ......................... 106

8.5.7 Replacing the cartridge in return oil filter............................... 108

8.5.8 Check gear oil ................................................................... 109

8.5.9 Change of gear oil.............................................................. 111

Table of Contents

Operator's Manual GB

8.6 Troubleshooting......................................................................... 112

8.6.1 Main fuses........................................................................ 112

8.6.2 Faults on the crane ............................................................. 113

8.6.3 Display [option]................................................................. 116

9. Decommissioning............................................................................... 118

9.1 Decommissioning a crane............................................................ 118

10. Technical Data .................................................................................. 120

10.1 Documentation .......................................................................... 120

10.2 Identification of the loader crane .................................................. 120

10.3 Theoretical using time Hoist ........................................................ 120

10.4 Performance Data TC1, rope capacity............................................ 121

10.5 Abbreviations............................................................................ 122

10.6 Daily inspection checklist to photocopy ......................................... 123

Introduction

Operator's Manual GB

1.1 This Operator's Manual is in-

tended for operators of this

HIAB crane.

This manual describes:

• Operation

• Safety precautions and warnings

• The crane control system

• Maintenance and troubleshooting

Enclosed to this manual the Installer will

provide:

• Technical Data for your crane

• Technical Data and manuals for add on

equipment if fitted

Study these instructions carefully

DANGER

If you do not study the complete Operator’s

Manual for your crane carefully, it could lead

to fatal accidents or serious damage.

Therefore you should:

• Study the entire Operator’s Manual carefully.

• Study the operating manuals for other add-on

equipment, if fitted.

• Use the crane only after having done so.

• Follow the directions for use, operation and

maintenance of the crane and add on equip-

ment exactly.

• Store the Technical Data and manuals from

the Installer, together with this Operator's

manual.

! NOTE

The manufacturer reserves the right to change

specifications, equipment, operating instructions

and maintenance instructions without prior notice.

Introduction

Operator's Manual GB

1.2

NOTE

HIAB shall at all times have the right to:

• install, maintain and dismantle automated re-

mote diagnostics system or similar sensor-

based system (the “System”) in and from the

Equipment; and

• access, send, receive, collect, store and use

any and all information and data gathered or

created by such System including but not

limited to information concerning operation,

operating environment, movement, condition,

logon, location and similar information relat-

ing to the Equipment (the “Information”).

The Customer shall not in any way remove or

alter the System, nor interfere with the use of the

System or the Information. The System and the

Information and all their further developments

shall at all times be and remain the exclusive

property of HIAB without granting any right or

license to the customer.

1.2 Cleanliness certificate

All Hiab equipment has been tested and certified

at the factory according to the Hiab Standard

C250.52 that defines the Cleanliness Require-

ments for Hydraulic Systems. This means that

they fulfil the cleanliness class 20/18/14 meas-

ured by the ISO 4406 standard.

All hydraulic functions have been individually

tested and fully comply with the defined require-

ments.

1.3 Indications in the Operator’s

Manual

What must you do and not do?

The following indications are used in the Opera-

tor’s Manual:

Introduction

Operator's Manual GB

1.3

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. .....

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.

Introduction

Operator's Manual GB

1.3

Symbol for reference to a component in an

illustration.

①Refers to a component in an illustration.

[option]: Indication for parts that are not-standard

for the crane, but are an option. Not all [option]

are available for your crane.

DANGER

Only persons with the requisite knowledge and

experience with cranes may use the crane.

Never operate the crane when you are sick,

tired, under the influence of medicines, alcohol

or other drugs.

• Take the delivery instructions from your

HIAB Service workshop, or receive instruc-

tion from an experienced person from your

own company. Only then should you operate

your crane.

• Ensure that you comply with the statutory

requirements of the country in which you use

the crane (for example, certificate, obligatory

safety-helmet).

DANGER

• Carry out yourself only the service and

maintenance work you have the requisite

knowledge and experience of.

• All other maintenance work may only be

carried out by a HIAB service workshop.

• Ensure that every defect is rectified imme-

diately, according to the instructions.

• Follow the instructions exactly!

• All other work to rectify faults must be

performed by personnel in a HIAB service

workshop!

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