HIAB X-HiPro 142 User manual

This operator’s manual is an Original Instruction
and applies for cranes from serial number:
BL142HP00001, BL162HP00001, BL192HP002953, BL232HP00001,
BL262HP00001, BL302HP00001
2017-02
Operator's Manual GB
HIAB X-HiPro
142/162/192/232/262/302

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]

3
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 Indications in the Operator’s Manual ................................................ 8
2. Structure and parts of the HIAB crane..................................................... 11
2.1 Main groups ............................................................................... 11
2.2 Crane base with column and slewing system .................................... 11
2.3 Stabiliser system.......................................................................... 12
2.4 Boom system .............................................................................. 13
2.5 Accessories on the boom system .................................................... 14
2.6 Operating system - hydraulic components ........................................ 17
2.7 LHV Load holding valves ............................................................. 18
2.8 Description of HIAB X-HiPro........................................................ 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........................................................... 24
3.3.2 Maximum load.................................................................... 24
3.3.3 Signs on the crane ............................................................... 27
3.3.4 Maximum load.................................................................... 27
3.3.5 Maximum load moment........................................................ 30
3.3.7 Lifting loads with hoist......................................................... 33
3.4 Signals when using a crane............................................................ 34
3.5 Use of the crane .......................................................................... 38
3.5.1 Preparations for use ............................................................. 40
3.5.2 Crane operation................................................................... 41
3.5.3 Service platform [option] ...................................................... 44
3.5.4 Driving with the crane.......................................................... 44
3.5.5 Use of the Hoist .................................................................. 44
3.5.6 Use of lifting equipment ....................................................... 46
3.5.7 Use of demountable cranes.................................................... 46
3.5.8 Ending crane operation ......................................................... 47
4. The HiPro system ................................................................................ 48

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Table of Contents
Operator's Manual GB
4.1 Control System SPACE X4 ........................................................... 48
4.2 How the safety system works......................................................... 48
4.3 Components of the HiPro system.................................................... 50
4.4 Main control valve....................................................................... 51
4.5 Different stabiliser control valves ................................................... 52
4.6 User panel.................................................................................. 53
4.6.1 Indicator LEDs on user panel................................................. 54
4.7 Dump valves............................................................................... 56
4.8 Pressure reduction filter ................................................................ 56
4.9 Lamp pole [option] ...................................................................... 57
4.10 XSDrive controller....................................................................... 57
4.10.1 Indicator LEDs on XSDrive controller..................................... 58
4.10.2 Buttons .............................................................................. 59
4.10.3 Menus ............................................................................... 61
4.10.4 Standard function symbols .................................................... 62
4.10.5 Battery and battery charger XSDrive....................................... 63
4.11 CombiDrive controller.................................................................. 64
4.11.1 Displays............................................................................. 65
4.11.2 Buttons .............................................................................. 67
4.11.3 Main menus........................................................................ 68
4.11.4 Battery and battery charger.................................................... 73
4.12 Control platform [option] .............................................................. 74
4.13 High seat [option]........................................................................ 74
5. Starting crane operation ........................................................................ 76
5.1 Starting operations ....................................................................... 76
5.2 Set the stabiliser system................................................................ 78
5.2.1 Stabiliser system and ground conditions .................................. 80
5.2.2 Activate the stabiliser system................................................. 81
5.2.3 Extend the stabiliser extensions.............................................. 81
5.2.4 Set the stabiliser legs............................................................ 83
5.3 Operate the boom system out of transport position ............................ 87
5.3.1 BDA Boom Deployment Assistance [option]............................ 89
6. During operation ................................................................................. 92

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Table of Contents
Operator's Manual GB
6.1 Functions ................................................................................... 92
6.2 OLP (Overload protection) ............................................................ 96
6.3 OLP - indications on the controller ................................................. 97
6.3.1 XSDrive............................................................................. 97
6.3.2 CombiDrive........................................................................ 98
6.4 To release OLP ........................................................................... 98
6.4.1 OLP release on user panel..................................................... 99
6.4.2 OLP release on controller XSDrive......................................... 99
6.4.3 OLP release on controller CombiDrive.................................... 99
6.5 Manual extensions [option] ........................................................... 99
7. Change from hoist to hook operation..................................................... 103
7.1 Change from hoist to hook operation............................................. 103
8. Ending crane operation ....................................................................... 107
8.1 Operate the boom system into transport position.............................. 107
8.1.1 ....................................................................................... 107
8.2 Placing the stabiliser system in the transport position ....................... 110
8.2.5 Retract the stabiliser extensions ............................................ 113
8.3 Switching off the control system................................................... 115
8.4 Emergency operation Valve-V200................................................. 116
8.5 TWI Transport warning interface.................................................. 118
9. Maintenance and Service..................................................................... 119
9.1 Service..................................................................................... 119
9.2 Warranty .................................................................................. 120
9.3 Follow the maintenance instructions!............................................. 121
9.3.1 Daily inspection................................................................. 122
9.3.2 Monthly inspection and maintenance..................................... 124
9.3.3 Annual maintenance ........................................................... 126
9.3.4 Hoist maintenance.............................................................. 126
9.3.5 Check rope ....................................................................... 128
9.3.6 Cleaning the rope............................................................... 128
9.3.7 Course and requirements of the rope ..................................... 129
9.3.8 Change of rope.................................................................. 130
9.3.9 Maintenance and monitoring of rope end ............................... 132

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Table of Contents
Operator's Manual GB
9.4 Lubrication ............................................................................... 132
9.4.1 Lubrication schedule........................................................... 134
9.4.2 Lubrication of rope guide and top roller................................. 135
9.4.3 Lubrication of the upper column bearing................................ 135
9.5 Hydraulics ................................................................................ 136
9.5.1 Slewing housing: checking the oil level/oil change .................. 136
9.5.2 Replacing the cartridge in return oil filter............................... 137
9.5.3 Replacing the cartridge in pressure reduction filter................... 138
9.5.4 Checking the oil tank level .................................................. 138
9.5.5 Changing the hydraulic oil................................................... 138
9.5.6 Check gear oil ................................................................... 141
9.5.7 Change of gear oil.............................................................. 142
9.5.8 Bleeding air from the hydraulic system.................................. 142
9.6 Troubleshooting......................................................................... 143
9.6.1 Main fuses........................................................................ 143
9.6.2 Faults on the crane ............................................................. 145
9.6.3 Faults in the hoist............................................................... 146
9.6.4 Display [option]................................................................. 148
10. Decommissioning............................................................................... 150
10.1 Decommissioning a crane............................................................ 150
11. Technical Data .................................................................................. 152
11.1 Documentation .......................................................................... 152
11.2 Theoretical using time Hoist ........................................................ 152
11.3 Performance Data TC1, rope capacity............................................ 153
11.4 Performance Data TC2, rope capacity............................................ 153
11.5 Abbreviations............................................................................ 154

7
Introduction
Operator's Manual GB
1
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.

8
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 Indications in the Operator’s
Manual
What must you do and not do?
The following indications are used in the Opera-
tor’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.

1
9
Introduction
Operator's Manual GB
1.2
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.
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.

10
Introduction
Operator's Manual GB
1.2
• 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!
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 oper-
ation as described in this manual.
• You should therefore study the Operating
Manual for the add-on equipment careful-
ly, before you use the crane.
• Take particular note when placing the
crane in to or out of transport position.

5
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Structure and parts of the HIAB crane
Operator's Manual GB
2
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:
• Manual extensions [option]
• Hoist [option]
• JIB [option]
• 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 sys-
tem consist of the following components:
• Crane base ①
with stabiliser beams ②and three-point
bridge ③
• Column ④
fitted to the crane base
• Rack and pinion slewing system ⑤

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2
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12
Structure and parts of the HIAB crane
Operator's Manual GB
2.3
2.3 Stabiliser system
Every HIAB crane is equiped with two stabiliser
extensions and two stabiliser legs. Auxiliary
stabiliser systems may be needed for heavy
cranes. The stabiliser system consists of:
①Stabiliser beam
②Stabiliser extensions
③Stabiliser legs
④Stabiliser locking devices [option]
⑤Extra support plates

1
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6
4
7
8
9
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Structure and parts of the HIAB crane
Operator's Manual GB
2.4
2.4 Boom system
The boom system consists of the following
components:
•①1st boom
•②2nd boom
•③Hydraulic extensions
The length of the hydraulic extension depends
on the type of crane.
•④Manual extensions [option]
•⑤Hoist [option]
•⑥Rope guide [option]
Only present if the crane is equipped with a
minimum of 3 hydraulic extensions.
•⑦Top roller [option]
The top roller must only be attached to a
hydraulic extension. Never to a manual exten-
sion.
•⑧Counterweight [option]
•⑨Hook [option]

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Structure and parts of the HIAB crane
Operator's Manual GB
2.5
2.5 Accessories on the boom system
Manual extensions [option]
Manual extension is slid by hand into the
hydraulic extension.
Hoist [option]
The hoist is a crane accessory which permits load
handling without any or only limited boom
movement. An obvious advantage is that the hoist
makes it possible to handle loads far below
ground level. Lifting and lowering is achieved by
winding/ unwinding the rope. A number of
auxiliary components are needed, such as inter-
mediate pulleys and a hook pulley. As an option,
a snatch block can be installed to duplicate lifting
capacity.

➀
➁
➄
➅
➂
➃
➆➇
15
Structure and parts of the HIAB crane
Operator's Manual GB
2.5
The Hoist consists of the following compo-
nents:
•Wear plate ①for rope end monitoring
•Pressure roller ②
•Rope ③
•Load sensor ④
•Electrical wire to load sensor ⑤
•Electronic box ⑥
•Switch ⑦for 3-rolls left to rope end
monitoring
•Motor ⑧

16
Structure and parts of the HIAB crane
Operator's Manual GB
2.5
Separate lifting accessories [option]
Separate lifting accessories, help to make or use a
slinging device: eye-hooks, shackles, eye-bolts
etc.
Hooks [option]
Different hooks can be mounted depending on the
crane model.
DANGER
Never exceed the maximum permissible load-
ing of the hook.
Personal basket [option]
Only permitted in MEWP cranes (Mobile Elevat-
ing Work Platform).

5
4
7
2
6
11 1
3
12
8
9
10
17
Structure and parts of the HIAB crane
Operator's Manual GB
2.6
2.6 Operating system - hydraulic
components
The operating system consists of the following
hydraulic components:
①Oil tank ⑤Stabiliser control valve
[option]
⑪Return filter
②Hydraulic pump ⑥Hydraulic hoses and
lines
⑫Load holding valve
③Oil cooler [option] ⑦Slewing cylinders / Mo-
tor reducers Pressure filter [option]
④Main control valve Actuators:
⑧First boom cylinder
⑨Second boom cylinder
⑩Extension cylinder/s

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Structure and parts of the HIAB crane
Operator's Manual GB
2.7
2.7 LHV Load holding valves
All cylinders are equipped with load-holding
valves as a safety device. After a crane move-
ment 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 re-
quired.
2.8 Description of HIAB X-HiPro
The HIAB
X-HiPro 142
X-HiPro 162
X-HiPro 192
X-HiPro 232
X-HiPro 262
X-HiPro 302
are compact, fully hydraulically operated loader
cranes.
The crane type and the manufacturer are marked
on the serial number plate.
The hoist [option] is designed for a HIAB crane,
installed on the second boom.
! NOTE
The exact technical information for your crane is
shown in the Technical Data.

19
Safety precautions and warnings
Operator's Manual GB
3
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 ex-
ceeds 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 get a good function of the crane, it should
be started as follows:
• Engage the power take-off at low rpm.
• Allow the system to idle for a few min-
utes.
• Operate stabiliser legs up and down for
one minute, in order to warm up the oil.

20
Safety precautions and warnings
Operator's Manual GB
3.2
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 move-
ment, 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 diffi-
culty.
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