HIAB 410K PRO User manual

HIAB 410K PRO
Operator's Manual GB
This operator’s manual is an Original Instruction and applies to cranes with serial number from:
4100056.
2021-07

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
1. Introduction ......................................................................................... 5
1.1. This Operator's Manual is intended for operators of this crane. ................... 5
1.2. Cleanliness certificate ................................................................... 6
1.3. Indications in the Operator’s Manual .................................................. 6
2. Structure and parts of the crane ................................................................. 9
2.1. Main groups .............................................................................. 9
2.2. Crane base with column and slewing system ........................................ 9
2.3. Stabiliser system ........................................................................ 9
2.4. Boom system .......................................................................... 10
2.5. Ladder .................................................................................. 11
2.6. Operating system - hydraulic components ......................................... 12
2.7. LHV Load holding valves ............................................................. 13
2.8. Description of HIAB 410K Pro ....................................................... 13
3. Safety precautions and warnings .............................................................. 14
3.1. Operating conditions .................................................................. 14
3.2. Wind speeds ........................................................................... 15
3.3. Definition of this loader crane ........................................................ 15
3.3.1. Noise declaration ............................................................ 17
3.3.2. Signs on the crane .......................................................... 17
3.3.3. Maximum load [AR+] ........................................................ 17
3.3.4. Maximum load moment ..................................................... 19
3.4. Signals when using a crane [AR+] .................................................. 21
3.5. Use of the crane ....................................................................... 25
3.5.1. Preparations for use ........................................................ 26
3.5.2. Crane operation ............................................................. 28
3.5.3. Driving with the crane ....................................................... 31
3.5.4. Use of lifting equipment .................................................... 32
3.5.5. Use of demountable cranes ................................................ 32
3.5.6. Ending crane operation ..................................................... 33
4. The Safety system ............................................................................... 34
4.1. Safety System SPACE 3000 ......................................................... 34
4.2. How the safety system works ........................................................ 34
4.3. Components of SPACE 3000 Safety System ...................................... 35
4.4. Operating components ................................................................ 35
4.5. Standard symbols and functions of the crane and the stabiliser system ........ 35
4.6. Main control valve ..................................................................... 37
4.7. Different stabiliser control valves .................................................... 37
4.8. High seat ............................................................................... 38
4.9. Selector valve .......................................................................... 38
4.10. OPS Operator Protection System [option] ........................................ 38
4.11. User panel SPACE 3000 ............................................................ 39
4.11.1. Indicator lights on User Interface SPACE 3000 ........................ 39
5. Starting crane operation ........................................................................ 41
5.1. Starting operations [AR+] ............................................................. 41
5.2. Stabiliser system and ground conditions ........................................... 43
5.3. Extend the stabiliser extensions ..................................................... 44
5.4. Set the stabiliser legs [AR+] .......................................................... 45
HIAB 410K PRO 3

5.5. Operate the boom system out of transport position ............................... 46
6. During operation ................................................................................. 49
6.1. OLP (Overload protection) ........................................................... 49
7. Ending crane operation ......................................................................... 51
7.1. Operate the crane to parking position ............................................... 51
7.2. Placing the stabiliser extensions and legs in transport position [AR+] .......... 52
7.3. Switching off the safety system ...................................................... 54
7.4. Emergency operation Valve-V91 .................................................... 54
7.5. Transport warning [option] ............................................................ 55
8. Maintenance and Service ....................................................................... 56
8.1. Service .................................................................................. 56
8.2. Warranty ................................................................................ 57
8.3. Follow the maintenance instructions! ............................................... 57
8.3.1. Daily inspection .............................................................. 60
8.3.2. Monthly inspection and maintenance ..................................... 64
8.3.3. Annual maintenance ........................................................ 65
8.4. Lubrication .............................................................................. 65
8.4.1. Lubrication schedule ........................................................ 66
8.4.2. Greasing the upper column bearing and three-point bridge ............ 67
8.4.3. Lubrication of slide pads in boom system ................................ 68
8.4.4. Lubrication of the hooks .................................................... 68
8.5. Checking and topping up oil levels .................................................. 69
8.5.1. Slewing housing: checking the oil level and topping up ................ 69
8.5.2. Checking of the oil level of the tank ....................................... 70
8.6. Replacement of filters ................................................................. 72
8.7. Bleeding air from the hydraulic system ............................................. 73
8.8. Troubleshooting ........................................................................ 74
8.8.1. Main fuses ................................................................... 74
8.8.2. Faults on the crane .......................................................... 74
9. Decommissioning ................................................................................ 77
9.1. Decommissioning a crane ............................................................ 77
10. Technical Data .................................................................................. 79
10.1. Documentation ....................................................................... 79
10.2. Identification of the loader crane ................................................... 79
10.3. Daily inspection checklist ........................................................... 80
10.4. Monthly inspection checklist ........................................................ 81
4 HIAB 410K PRO

1. Introduction
1.1. This Operator's Manual is intended for operators of this
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 equipment 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
HIAB 410K PRO 5

NOTE
Hiab shall at all times have the right to:
• install, maintain and dismantle remote diagnostics tools or similar sensor-based
connectivity capabilities (“Connectivity”) in and from the Equipment; and
• access, send, receive, collect, store and use any and all information and data
gathered through the Connectivity, including but not limited to, information
concerning efficiency, availability, downtime, operation, operating environment,
movement, condition, logon, location and similar information relating to the
Equipment (the “Information”). Such Information may be used for optimizing the
Equipment, or any related equipment or services as well as for Hiab's internal
business and/or operating purposes. Hiab shall be responsible for complying
with applicable laws and regulations related to such Information.
The customer/user shall not in any way remove, disable, or interfere with the
Connectivity or the Information. Any intellectual property rights or other right and
title in and to the Connectivity features and the Information and all their further
developments shall at all times be and remain the exclusive property of Hiab.
1.2. Cleanliness certificate
All Hiab equipment has been tested and certified at the
factory according to the Hiab Standard C250.52 that
defines the Cleanliness Requirements for Hydraulic
Systems. This means that they fulfil the cleanliness class
20/18/14 measured by the ISO 4406 standard.
All hydraulic functions have been individually tested and
fully comply with the defined requirements.
1.3. Indications in the Operator’s Manual
What must you do and not do?
The following indications are used in the Operator’s Manual:
DANGER
Danger to life for yourself or to bystanders.
Follow the instructions carefully!
WARNING
Danger of injury to yourself or to bystanders, or danger of serious damage to the
crane or other objects.
Follow the instructions carefully.
Introduction
6 HIAB 410K PRO

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.
The symbol for reference to a component in an illustration.
(1) Refers to a component in an illustration.
[option]: Indication for parts that are not standard for the
crane, but are optional. Not all options are available for
your crane.
Illustrations used in this manual are for guidance only, and
the illustrations are provided to help identify the general
area of a crane/installation referenced in the text.
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 authorised service workshop, or receive instruction
from an experienced person from your own company before you start to operate your crane.
• Make sure that you comply with the regulations of the country in which you use the crane (for
example, certificate, safety helmet, and other personal protection devices).
1
Introduction
HIAB 410K PRO 7

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 authorised service
workshop.
• Make sure 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
authorised service workshop!
WARNING
• Never clean the electronic system, plastic components, signs, or bearings with a
high-pressure jet cleaner. It could cause damage.
• Never expose the electronic system to high electrical voltages. This could
damage the control system.
• Never immerse the controller in water or other liquid. This will make the
controller unusable.
If your crane is equipped with add-on lifting equipment (hoist, rotator, etc.):
• The operation of the crane with add-on lifting equipment can differ 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 into or out of the transport position.
Introduction
8 HIAB 410K PRO

2. Structure and parts of the crane
2.1. Main groups
This HIAB crane consists of the following main groups:
• Crane base with column and slewing system
• Stabiliser system
• Boom system
• Operating system - hydraulic components
Some accessories can be fitted depending on your crane configuration:
• Add-on lifting accessories [option]
• Hooks [option]
• Separate lifting accessories [option]
2.2. Crane base with column and slewing system
The crane base, column and the slewing system
consist of the following components:
(1) Crane base
(2) Stabiliser beam
(3) Three-point bridge
(4) Column
(5) Rack and pinion slewing system.
2.3. Stabiliser system
HIAB cranes (except stationary mounted) have two
stabiliser extensions and two stabiliser legs. Auxiliary
stabiliser systems may be needed for bigger cranes. The
stabiliser system consists of:
(1) Stabiliser beam
(2) Stabiliser extensions
(3) Stabiliser legs
(4) Stabiliser locking devices [option]
(5) Extra support plates
1
2
3
4
5
1
2
3
4
5
Structure and parts of the crane
HIAB 410K PRO 9

2.4. Boom system
The boom system consists of the following components:
• 1st boom (1)
• 2nd boom (2)
• Hydraulic extensions (3)
The extensions are operated by hydraulic cylinders
placed inside the extensions.
•Add-on lifting accessories [option]
Add-on lifting accessories are placed between the boom tip
and the load (e.g. pallet fork, grapple, rotator).
Hooks [option]
Different hooks can be mounted depending on the crane
model.
DANGER
Never exceed the maximum permissible loading of the hook.
Separate lifting accessories [option]
Separate lifting accessories, help to make or use a slinging
device: shackles, eye-bolts etc.
3
2
1
Structure and parts of the crane
10 HIAB 410K PRO

2.5. Ladder
The access to the high seat is through a ladder placed at
one side of the base.
Structure and parts of the crane
HIAB 410K PRO 11

2.6. Operating system - hydraulic components
The operating system consists of the following hydraulic components:
12
3
4
5
6
7
8
9
10
11
12
(1) Oil tank (5) Stabiliser control valve [option] (11) Return filter
(2) Hydraulic pump (6) Hydraulic hoses and lines (12) Load holding valve
(3) Oil cooler [option] (7) Slewing cylinders / Slewing motors Pressure filter [option]
(4) Main control valve Actuators:
(8) First boom cylinder
(9) Second boom cylinder
(10) Extension cylinder/s
Structure and parts of the crane
12 HIAB 410K PRO

2.7. 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 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
lever.
To operate a hydraulic cylinder equipped with a load
holding valve, an opening pressure is required.
2.8. Description of HIAB 410K Pro
The HIAB 410K Pro are compact, fully hydraulically operated goods cranes.
Stress history class S1 according to EN 13001-1.
Lifting capacity:
• HIAB 410K = 29.7 tonne metres (214800 lbs.ft)
The cranes are supplied in a version:
• HIAB 410K-3 reach: 22.5 metres (73' 9" ft)
The main control valve V91 and the SPACE 3000 safety system are standard equipment on the
HIAB 410K Pro.
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.
Structure and parts of the crane
HIAB 410K PRO 13

3. Safety precautions and warnings
3.1. Operating conditions
You may use the crane ONLY if:
• You are outdoors or in a space with sufficient ventilation.
• With a mean wind velocity of less than 13.3 m/sec (approx. 29.7 mph). See the wind speed
table.
DANGER
•Do not use the crane in a confined space because 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 -30°C (-22°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.
• In cold weather, the wear on the hydraulic
system is greater than at normal working
temperatures.
In cold weather, start the crane as follows:
• Engage the power take-off at low rpm.
• Allow the system to idle for a few minutes.
• Operate stabiliser legs up and down for
one minute, in order to warm up the oil.
Safety precautions and warnings
14 HIAB 410K PRO

3.2. Wind speeds
Wind speed averaged over 10 minutes at a height of 10 m
Wind
Force
Above flat ground Characteristics
m/s Wind type
0 0.0 - 0.2 Calm Calm, smoke rises vertically or nearly
vertically
1
2
0.3 - 1.5
1.6 - 3.3
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.
3
4
3.4 - 5.4
5.5 - 7.9
Moderate wind Leaves and twigs in continuous movement,
small branches begin to move. Dust and
paper begin to move over the ground.
5 8.0 - 10.7
Fairly strong
wind
Small leaved branches make swaying
movements; crested waves form on lakes
and canals.
6 10.8 - 13.8
Strong wind Large branches move; you can hear the
wind whistling in telephone wires; umbrellas
can only be held with difficulty.
7 13.9 - 17.1 Severe wind Entire trees move; the wind causes difficulty
when you walk into it.
8 17.2 - 20.7 Stormy wind Twigs break off, walking is difficult.
9 20.8 - 24.4
Storm Causes superficial damage to buildings
(chimney pots, roof-tiles, and TV antennae
are blown off).
10 24.5 - 28.4 Severe storm Uprooted trees; considerable damage to
buildings etc. (occurs infrequently on land).
11 28.5 - 32.6 Very severe
storm
Causes extensive damage (occurs very infre
quently on land).
12 > 32.6 Hurricane
3.3. Definition of this 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:
Safety precautions and warnings
HIAB 410K PRO 15

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
• Moving filling material at a construction site with a bucket
• 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…
Forbidden duties:
• Crane mounted onboard ships or floating structures, only permitted in cases authorised 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
• Pressure against the ground, unless the crane is specifically prepared for this
• Pushing/pulling with the boom system against any type of obstacle (wall, ground…)
• Putting loads on structures if you do not know their resistance
• Lifting loads with the wrong side of the boom system
• Lifting a mass that is partially loaded or attached to another equipment/structure/element
CAUTION
There is a risk of tipping the truck and/or damaging the crane, the load or other
structures inside the working area.
Safety precautions and warnings
16 HIAB 410K PRO

DANGER
Lifting people with a crane is never allowed unless it is a MEWP crane.
3.3.1. 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 dual-
number 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).
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.
3.3.2. Signs on the crane
3.3.3. Maximum load [AR+]
Lifting capacity
Safety precautions and warnings
HIAB 410K PRO 17

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.
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:
• 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.
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.
Safety precautions and warnings
18 HIAB 410K PRO

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 object 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.
3.3.4. 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.
Safety precautions and warnings
HIAB 410K PRO 19

If the 2nd boom is raised, the following movements are
locked:
• 1st boom down/up
• 2nd boom down
• extension boom out
If the 2nd boom is down, the following movements are
locked:
• 1st boom up
• 2nd boom up
• extension boom out
• 1st boom down (certain crane types and cases)
Lifting the load
Make sure 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.
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 multi-legged
sling for general purposes, is calculated by multiplying the
WLL of a single leg by a mode factor (refer to 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 is more than 90°, do not hang the slings directly on the
hook. Use a ring hanging from the hook to attach the sling.
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.
>120º
Safety precautions and warnings
20 HIAB 410K PRO