HIAB 190T Guide

Ver. : HIAB190T-201309
190T
OPERATING MANUAL
& SPARE PARTS LIST
EN
Cargotec Korea Ltd

190T
OPERATING MANUAL
EN
Cargotec Korea Ltd

- 3 -
Contents
1. Foreword - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 5
2. Safety - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 6
3. Technical description - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 8
3 - 1. Specification - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 8
3 - 2. Outline view - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 9
3 - 3. Lifting capacity table & working radius - - - - - - - - - - - - 10
3 - 4. Hydraulic diagram - - - - - - - - - - - - - - - - - - - - - - - - - - 11
4. General description - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 12
4 - 1. Basic operation principle - - - - - - - - - - - - - - - - - - - - - - 12
4 - 2. Main components - - - - - - - - - - - - - - - - - - - - - - - - - - - 13
4 - 3. Base - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 14
4 - 4. Column - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 14
4 - 5. Boom system - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 15
4 - 6. Control valve - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 15
4 - 7. Outrigger system - - - - - - - - - - - - - - - - - - - - - - - - - - - 16
4 - 8. Winch - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 17
4 - 9. PTO & Pump [Option] - - - - - - - - - - - - - - - - - - - - - - - - - 17
4 - 10. Oil tank [Option] - - - - - - - - - - - - - - - - - - - - - - - - - - - - 18
4 - 11. Top seat [Option] - - - - - - - - - - - - - - - - - - - - - - - - - - - - 18
4 - 12. OLP (over load protection) system [option] - - - - - - - - - 19
4 - 13. Anti two block system [Option] - - - - - - - - - - - - - - - - 19

- 4 -
5. Operating - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 20
5 - 1. Before operating the crane - - - - - - - - - - - - - - - - - - - - 20
5 - 2. Warming up when cold weather - - - - - - - - - - - - - - - - - 20
5 - 3. Operating the outrigger - - - - - - - - - - - - - - - - - - - - - - - 21
5 - 4. Operating of crane - - - - - - - - - - - - - - - - - - - - - - - 22
5 - 5. Over winding alarm [Option] - - - - - - - - - - - - - - - - - - - - 24
5 - 6. After operating the crane ( for driving ) - - - - - - - - - - - - 25
6. Safety instruction when operating - - - - - - - - - - - - - - - - - - - - 26
7. Preventive Service & Maintenance - - - - - - - - - - - - - - - - - - - 28
7 - 1. Daily inspection - - - - - - - - - - - - - - - - - - - - - - - - - - - - 28
7 - 2. Slewing bearing & mounting bolts - - - - - - - - - - - - - - - 29
7 - 3. Wire rope - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 29
7 - 4. Changing a filter insert - - - - - - - - - - - - - - - - - - - - - - - 33
7 - 5. Inspection point when operating - - - - - - - - - - - - - - - - - 35
7 - 6. Inspection after operating - - - - - - - - - - - - - - - - - - - - - 35
7 - 7. Inspection & maintenance after 1 month operation - - - 35
7 - 8. Inspection & maintenance after 6 months operation - - - 36
8. Lubrication - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 38
8 - 1. Hydraulic oil changing - - - - - - - - - - - - - - - - - - - - - - - - 38
8 - 2. Lubrication chart - - - - - - - - - - - - - - - - - - - - - - - - - - - - 40
9. Fault tracing - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 41
Appendix 1 : Wind speeds - - - - - - -- - - - - - - - - - - - - - - - - - - 43

- 5 -
1. Foreword
This operator’s manual for Hiab190T-6 teaches you the
right way to operate and maintain your crane.
Therefore it is very important that you read this operator’s
manual before you start using the crane.
The manual gives you a short description of the crane as
well as some instructions and maintenance advices. To
give the crane a long life you should always follow this
instructions.
For maintenance, in excess of greasing and simpler
repairs which you easily can do by yourself, you should
consult your Hiab dealer or service center which has
trained personnel.
We reserve the right that without advance notice change
data and equipment as well as maintenance procedures.

- 6 -
2. Safety instruction
zBefore operating the crane, a basic knowledge of the
operation and safety measures of the crane must be
acquired.
zBefore operating the crane, the outrigger (stabilizer)
beam should be extended and the outrigger shoe
(stabilizer foot plate) should be firmly settled on the
ground.
zDuring operation, unauthorized person should keep out
of the working area of the crane.
zThe operation below or in the vicinity of any kind of
electric cables or wires is highly dangerous and must
never be permitted. Please refer to local regulations for
minimum working distances between the crane and
overhead power lines.
zNever use the crane in a high wind or storm.
When mean wind speed exceeds 13.3m/sec, the crane
will behave unpredictably.

- 7 -
zNever exceed the maximum capacity given on the
crane capacity plate.
Load capacity indicated on the crane capacity plate
is the total weight including the hook weight.
zNever slew until the load is clear of the ground.
zNever walk or stand below a suspended load.
zBefore operating the crane, never forget to check the
condition of the wires.
zBe careful when using acceleration in suspended load.
zAfter operation, hook is to be secured for driving.
zPrecautions shall be taken when disconnecting
hydraulic tubing and hoses to ensure that no hydraulic
pressure is retained in the line when the power supply
to the system is switched off.

- 8 -
3. Technical description
3 - 1 Specification
Description Specification Remarks
Lifting Capacity 18.1 ton-m
Working Radius 19.5 m
Outreach - Lifting Capacity
1.62 m - 8,000 kg
3.88 m - 3,630 kg
6.89 m - 2,050 kg
10.45 m - 1,300 kg
15.57 m - 770 kg
19.47 m - 440 kg
Working Height above ground
level 20.6 m
Recommended oil Flow 63 ℓ/ min
Working pressure 210 bar
Boom
Type Hexagonal, 6 sections
Lifting angle/speed 0 ~ 80 deg / 15 sec
Extension speed 14.45m / 33 sec
Winch
Type Spur gear reduction type
with mech. brake
Lifting capacity 8,000 kg ( 4 falls )
Speed min. 8 m/min ~ max.
11m/min (4 falls)
Slewing
Type Worm gear reduction
Angle 360 deg Continuous
Speed 1.8 rpm
Outrigger Span 5.7 m
Safety function
Counter balance valve
Hyd. Swing brake
Pilot check valve
Hook latch
Pressure relief valve
Auto Winch brake
Weight with outrigger 3,250 kg (about)

- 9 -
3 - 2 Outline view

- 10 -
3 - 3 Lifting capacity table & working radius
boom angle
1st boom 2nd boom 3rd boom 4th boom 5th boom 6th boom
R(m) Q(kg) R(m) Q(kg) R(m) Q(kg) R(m) Q(kg) R(m) Q(kg) R(m) Q(kg)
80 deg 0.75 8,000 1.25 6,800 1.75 4,500 2.25 2,400 2.76 1,800 3.26 920
70 deg 1.62 8,000 2.61 5,000 3.60 3,560 4.58 2,400 5.57 1,800 6.56 920
60 deg 2.44 6,320 3.88 3,630 5.33 2,550 6.77 1,940 8.22 1,540 9.66 920
50 deg 3.17 5,250 5.03 2,950 6.89 2,050 8.75 1,540 10.60 1,210 12.46 920
40 deg 3.81 4,610 6.02 2,540 8.24 1,750 10.45 1,300 12.67 1,010 14.88 810
30 deg 4.33 4,170 6.83 2,260 9.33 1,540 11.84 1,140 14.34 880 16.84 700
20 deg 4.71 3,840 7.42 2,050 10.14 1,390 12.86 1,010 15.57 770 18.28 610
10 deg 4.94 3,500 7.79 1,850 10.63 1,240 13.48 900 16.33 680 19.17 520
0 deg 5.02 3,170 7.91 1,650 10.80 1,100 13.69 780 16.58 580 19.47 440

- 11 -
3 - 4 Hydraulic diagram

- 12 -
4. General Description
4 - 1 Basic operation principle
Hiab 190T crane consists of mainly steel structures and
hydraulic components.
The required power source for crane operation comes,
via the chassis’ power take off (PTO), from the hydraulic
pump giving high pressure hydraulic oil. This high
pressure oil operates the cylinders and motors through
the control valve and returns to the oil tank.

- 13 -
4 - 2 Main components
1) Base
2) Column
3) Boom system
4) Control valve
5) Winch
6) Outrigger system
7) PTO & Pump
8) OIL TANK
9) TOP SEAT

- 14 -
4 - 3 Base
The base is connected with the column structure by
slewing bearing, which makes the crane rotate, and is
mounted on the chassis frame with strong anchor
bolts.
4 - 4 Column
The column is of a closed
welded box design and
connected with the base.
The column supports the boom
system via derrick cylinder.
The winch system is mounted in
the column structure.

- 15 -
4 - 5 Boom system
The boom system consists of main boom, six
extension booms and extension cylinders moving
each boom.
The three cylinders are of a double acting type. The
counter balance valve of each cylinder makes the
cylinders operate at constant speed regardless of the
suspended load.
4 - 6 Control Valve
The Hiab 190T stiff boom crane is equipped with
two(2) 4-function control valves connected serially.
One is for main controls of the crane (slewing, boom
lifting, extension, winch), and the other is for the
outrigger control (outrigger beam extending, outrigger
jack cylinder). Both valves are equipped with built-in
main relief and port relief valves shown in the
hydraulic diagram. The relief valves makes that the
crane can not lift in excess of the designed load chart.

- 16 -
4 - 7 Outrigger system
The outrigger system consists of outrigger beam and
legs which make the chassis stable when the crane is
operating. The pilot check valves are installed on leg
cylinders to prevent the leg cylinders to go down
when driving and from hose failure when operating
the crane. Before operating the crane, spread the
outrigger and settle the outrigger firmly on the ground
to prevent tilting or too much stress on tires and
frame of the chassis.

- 17 -
4 - 8 Winch
The winch consists of hydraulic motor, gearbox and
winch drum. The winch is installed inside of the
column structure. The mechanical brake is included
in winch gearbox.
4 - 9 PTO & pump [Option]
The PTO is mounted the gearbox of the chassis. This
rotating power rotates the pump creating high
hydraulic oil pressure. The cylinders and motors are
activated by this high pressure oil.
The PTO is designed according to the chassis, so
you must consult the chassis manufacturer when you
select the PTO.

- 18 -
4 - 10 Oil Tank [Option]
The Hiab 190T crane is equipped with an oil tank for
separate mounting.
The oil tank consists of tank body Itself, return filter,
suction strainer, air breather, oil level gauge and drain
plug which can be used for drainage of the water or
some dirt accumulated in the tank bottom.
4 - 11 Top seat [Option]
4-function main control valve which controls slewing,
boom lifting, extension, winch is mounted on the top
seat with manual acceleration pedal to control chassis’
rpm. Also the top seat can be adjusted to fit operator’s
body.

- 19 -
4 - 12 OLP (over load protection) system [option]
The OLP system is a fully hydraulic concept that stops
the main hydraulic flow when the pressure in the derrick
cylinder has reached the maximum allowable level,
preventing aggravating movements.
The safety system resets automatically after a pressure
decreasing movement.
Although the safety system is triggered by the pressure
of the derrick cylinder only, it prevents all aggravating
movement. Only the extension can be moved inwards
as an exception, to solve the overload situation. The
crane and vehicle have a guaranteed stability.
4 - 13 Anti two block system [Option]
When hook hit the limit switch, send signal to solenoid.
The wire rope up and extending boom were stopped in
order to prevent over-winding.

- 20 -
5. Operation
5 - 1 Before operating the crane
zSecure the hand brake of the chassis
zCheck the oil level in the hydraulic oil tank
zEngage the PTO
zExtend the outrigger beam and down the outrigger
legs firmly on the ground
5 - 2 Warming up when cold weather
In cold weather, the viscosity of the operating oil
could be very high. It can make some damages to the
hydraulic components. Please warm up as follows.
zEngage the PTO and run the hydraulic oil pump
at low RPM.
zAfter 10-15 minutes without movement of the
control valve, operate the crane slowly.