HYVA HC1151 User manual

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SE ER R M
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HC C1 11 15 51 1
ORIGINAL INSTRUCTIONS
7845436-01 11/18
subject to change without notice

USER MANUAL
HC1151
INDEX
7845436-01 11/18
subject to change without notice
AWARNINGS .....................................................................................................................A.1
A.1PERSONAL PROTECTIVE EQUIPMENT.................................................................................................A.1
A.2MECHANICAL HAZARDS ........................................................................................................................A.2
A.2.1MECHANICAL RESISTANCE ...................................................................................................................A.2
A.2.2CRUSHING HAZARD................................................................................................................................A.4
A.2.3CUTTING HAZARD...................................................................................................................................A.5
A.2.4IMPACT HAZARD .....................................................................................................................................A.6
A.2.5OIL LEAK HAZARD...................................................................................................................................A.7
A.2.6LOSS OF STABILITY ................................................................................................................................A.8
A.2.7SLIPPING AND FALLS............................................................................................................................A.10
A.3ELECTRIC SHOCK HAZARD.................................................................................................................A.11
A.3.1CONTACT WITH LIVE COMPONENTS..................................................................................................A.11
A.3.2STATIC ELECTRICITY............................................................................................................................A.12
A.4HEAT HAZARDS ....................................................................................................................................A.12
A.4.1BURNS ....................................................................................................................................................A.12
A.5NOISE HAZARDS ...................................................................................................................................A.12
A.6VIBRATION HAZARDS ..........................................................................................................................A.13
A.7HAZARDS DUE TO TOXIC SUBSTANCES ...........................................................................................A.13
A.8ERGONOMIC HAZARDS........................................................................................................................A.14
A.8.1MANUAL OPERATIONS .........................................................................................................................A.14
A.8.2VISIBILITY............................................................................................................................................... A.14
A.8.3HUMAN ERROR .....................................................................................................................................A.14
A.9UNEXPECTED START-UP AND SWITCH-OFF OF THE CRANE .........................................................A.15
A.10SAFETY DEVICE FAULTS .....................................................................................................................A.15
A.11COUPLING FAULTS...............................................................................................................................A.17
A.12HAZARDS DUE TO INCORRECT LIFTING OPERATIONS...................................................................A.19
A.13HOW TO TRANSPORT THE CRANE.....................................................................................................A.22
A.14WARNINGS FOR JIB..............................................................................................................................A.23
A.15WARNINGS FOR WINCH .......................................................................................................................A.24
A.16WARNINGS FOR DRILL.........................................................................................................................A.26
BUSER MANUAL...............................................................................................................B.1
B.1PREMISE ..................................................................................................................................................B.1
B.2IDENTIFICATION......................................................................................................................................B.2
B.3DESCRIPTION AND DOCUMENTATION.................................................................................................B.3
B.3.1ENCLOSED DOCUMENTATION ..............................................................................................................B.3
B.3.2MARK ........................................................................................................................................................B.3
B.3.3SERVICE CONDITIONS ...........................................................................................................................B.4
B.3.4MAIN COMPONENTS ...............................................................................................................................B.5
B.4CONTROLS ..............................................................................................................................................B.6
B.4.1STABILIZERS CONTROLS.......................................................................................................................B.6
B.4.2RADIO REMOTE CONTROL ....................................................................................................................B.7
B.4.3EMERGENCY CONTROLS ON COLUMN.............................................................................................. B.10
B.5SAFETY DEVICES..................................................................................................................................B.11
B.5.1EMERGENCY STOP BUTTON ...............................................................................................................B.11
B.5.2OIL COOLER...........................................................................................................................................B.11
B.5.3LOCKING DEVICES FOR STABILIZERS ...............................................................................................B.12
B.5.4MOMENT LIMITER..................................................................................................................................B.13
B.5.5LIFT CONTROL SYSTEM (LCS).............................................................................................................B.13
B.5.6ROTATION CONTROL SENSOR (HRCS) .............................................................................................. B.14
B.6GAUGES AND INDICATORS .................................................................................................................B.15
B.6.1GAUGES ON OIL TANK..........................................................................................................................B.15
B.6.2OIL LEVEL INDICATOR ON GEAR UNITS.............................................................................................B.16
B.6.3LOAD INDICATOR ..................................................................................................................................B.16
B.6.4VISUAL-AUDIBLE WARNING DEVICES IN CABIN................................................................................B.17
B.6.5WARNING LABELS.................................................................................................................................B.17
B.7OPERATING THE CRANE .....................................................................................................................B.18
B.7.1PRELIMINARY CHECKS BEFORE OPERATION................................................................................... B.18
B.7.2START-UP OPERATION.........................................................................................................................B.19
B.7.3START-UP OPERATION AT LOW TEMPERATURE.............................................................................. B.19
B.7.4HOW TO DEPLOY THE STABILIZERS ..................................................................................................B.20
B.7.5OPENING PROCEDURE ........................................................................................................................B.22
B.7.6HOW TO READ THE LOAD CHARTS ....................................................................................................B.23
B.7.7LIFTING OPERATIONS ..........................................................................................................................B.23
B.7.8CLOSING PROCEDURE.........................................................................................................................B.24
B.7.9HOW TO FOLD THE STABILIZERS .......................................................................................................B.26
B.7.10USE WITH JIB.........................................................................................................................................B.29

USER MANUAL
HC1151
INDEX
7845436-01 11/18
subject to change without notice
B.7.11USE WITH ADDITIONAL STABILISERS.................................................................................................B.33
B.7.12USE WITH WINCH..................................................................................................................................B.34
B.7.13COMPULSORY CHECKS BEFORE LEAVING THE WORK PLACE ...................................................... B.36
CMAINTENANCE...............................................................................................................C.1
C.1WARRANTY TERMS ................................................................................................................................C.1
C.2ORDINARY MAINTENANCE ....................................................................................................................C.1
C.2.1GREASING................................................................................................................................................C.1
C.2.2FILLING UP THE OIL TANK......................................................................................................................C.4
C.2.3CLEANING THE CRANE...........................................................................................................................C.4
C.2.4WIRE ROPE MAINTENANCE ...................................................................................................................C.5
C.3PLANNED MAINTENANCE......................................................................................................................C.5
C.4EXTRAORDINARY MAINTENANCE ........................................................................................................C.5
C.5INACTIVITY...............................................................................................................................................C.5
C.6TAKING THE CRANE OUT OF SERVICE................................................................................................C.6
C.6.1DISASSEMBLY .........................................................................................................................................C.6
C.6.2STORAGE .................................................................................................................................................C.6
C.6.3DISPOSAL.................................................................................................................................................C.6
DTECHNICAL SHEET........................................................................................................D.1
D.1CRANE'S TECHNICAL DATA ..................................................................................................................D.2
D.2WINCHES' TECHNICAL DATA ................................................................................................................D.3
D.3OVERALL DIMENSIONS..........................................................................................................................D.4
D.4BASE DIMENSIONS AND MOUNTING BOLTS.......................................................................................D.5
D.5LIFTING HEIGHT CLOSE TO THE COLUMN ..........................................................................................D.6
D.6LOAD CHARTS FOR USE WITH HOOK..................................................................................................D.7
D.7LOAD CHARTS FOR TC2L WINCH IN SINGLE LINE ...........................................................................D.12
D.8LOAD CHARTS FOR TC2L WINCH IN DOUBLE LINE .........................................................................D.16
D.9LOAD CHARTS FOR TC3 WINCH IN SINGLE LINE .............................................................................D.20
D.10LOAD CHARTS FOR TC3 WINCH IN DOUBLE LINE ...........................................................................D.24
D.11WEIGHTS AND CENTERS OF GRAVITY ..............................................................................................D.27
D.12HOOK DATA...........................................................................................................................................D.28
D.13ATTACHMENTS FOR HOOK AND PULLEY .........................................................................................D.30
D.14HYDRAULIC SYSTEM............................................................................................................................D.31
D.15OIL COOLER ..........................................................................................................................................D.32
D.16ADDITIONAL STABILIZERS ..................................................................................................................D.33
D.17RECOMMENDED ADDITIONAL LIFTING TOOLS.................................................................................D.34
EANNEXES........................................................................................................................E.1
E.1HYDRAULIC SCHEMATICS.....................................................................................................................E.1
E.2WARNING LABELS..................................................................................................................................E.8
E.3TIGHTENING TORQUES........................................................................................................................E.11
E.4SELECTION OF HYDRAULIC OIL .........................................................................................................E.12
E.5BEARING CAPACITY OF SOILS ...........................................................................................................E.13
E.6BEAUFORT SCALE................................................................................................................................E.13
E.7TROUBLESHOOTING ............................................................................................................................E.14
E.8EC DECLARATION OF CONFORMITY..................................................................................................E.16
E.9MAINTENANCE REGISTER...................................................................................................................E.17
E.10EXTRAORDINARY MAINTENANCE MODULE .....................................................................................E.21

USER MANUAL
HC1151
WARNINGS
A.17845436-01 11/18
subject to change without notice
A WARNINGS
A.1 PERSONAL PROTECTIVE EQUIPMENT
During normal crane operations the users must wear:
- helmet
- safety gloves
- industrial footwear
- overalls secured using buttons and without loose or baggy parts
- high visibility clothing
IN ADDITION
oil-proof gloves and safety goggles during maintenance tasks.
ear protection if the noise level in the operating position exceeds 80 dB(A).
a dust mask in the presence of dusts.
a suitable mask in the presence of toxic fumes or poison gas.
Protective equipment
Standard protective equipment
during any crane operation
Additional protective equipment
during crane maintenance
Additional protective equipment
if the noise level exceeds 80 dB(A)
Additional protective equipment
in the presence of dusts
Additional protective equipment
in the presence of toxic fumes or poison gas

USER MANUAL
HC1151
WARNINGS
A.27845436-01 11/18
subject to change without notice
A.2 MECHANICAL HAZARDS
A.2.1 MECHANICAL RESISTANCE
The main hazards resulting from failure to follow the operating instructions described in the user
manual are listed below:
ENVIRONMENTAL TEMPERATURE
- Weakening of the crane structure
- Hydraulic oil viscosity too low/high
- Hydraulic oil overheating
- Weakening of plastic components
- Degradation of flexible hoses (-40°C 100°C)
INCLINATION OF THE CRANE'S BASE
- Crane rotation not possible
- Overpressure in slewing cylinders
- Overstress in bearing ring
- Overstress in crane structure
- Loss of stability
INCLINATION OF THE CRANE'S BOOMS
When the crane works with the booms in a near-vertical alignment (lifting moment is near zero), the
load limiting device could operate without the expected accuracy due to:
- oscillations / accelerations of the booms
- inclination of the vehicle
- wind
- joint clearances, frictions
This could cause:
- Overstress in crane structure
- Loss of stability
OIL FLOW RATE TO MAIN CONTROL VALVE
- Overstress in crane's structure caused by excessive speed of movement
- Excessive oil temperature
WIND SPEED
- Overstress in crane structure
- Excessive oscillation of the load
- Loss of stability
PRECIPITATION
- Lightening, electric shock
- General malfunctioning of the electric system
USE IN EXPLOSIVE ENVIRONMENTS
- Flammable hydraulic fluid and plastic components
INSTALLATION ON RIGID BASE
- Excessive forces of inertia
USE IN MARINE ENVIRONMENT
- Corrosion of structural components: cylinder rods, pins, winch rope (offshore cranes)
- Excessive forces due to oscillation/inclination (ship-mounted cranes)

USER MANUAL
HC1151
WARNINGS
A.37845436-01 11/18
subject to change without notice
LIFTING COMPONENT
- Excessive forces if lifting components other than hook are used
IP PROTECTION LEVEL
- Electric system faults (safety and controls)
WARNINGS
- Do NOT use the crane if the operating conditions are incompatible with the instructions given in
this manual. Specifically, the user must contact the manufacturer of the crane in the event of
environmental temperatures outside the range indicated in this manual.
- Handling of loads at heights requires full risk assessment: strictly adhere to the load charts and
always fully extend the stabilizers.
- Clear any snow or ice from the crane arms to prevent excessive stress caused by the extra weight
and to ensure that movement of telescopic components is not affected.
- Contact an authorised assistance centre before using or transporting the crane in a marine
environment.
- The lifting component to which the diagrams refer in this manual is the crane hook. If other lifting
components are to be used the user must contact an authorised assistance centre to obtain
dedicated load diagrams.
- Maintenance on the machine which requires welding or grinding is forbidden. Refer to an
authorised Service Centre if repairs or modifications to metalwork are required.

USER MANUAL
HC1151
WARNINGS
A.47845436-01 11/18
subject to change without notice
A.2.2 CRUSHING HAZARD
Crushing hazards derive from moving components on the crane:
body crushing between the crane and vehicle
upper limb crushing between base and crane booms
body crushing between stabilisers and a stationary object during stabilizer opening
limb crushing when stabiliser legs are retracted
lower limb crushing under the plate of the stabiliser cylinders
limb crushing in openings
WARNINGS
- Cordon off the working area using barriers and warning signs before starting any operations with
the crane. Use special signals to warn others when crane movement is about to start. Avoid
hazardous situations in which the user or other personnel may be crushed by the crane,
stabilizers or the load.
- Do NOT climb on to the crane base when the vehicle's engine is running.
- When handling the crane, avoid grasping the control levers: operate them only with the fingers.
- Keep all personnel away from the hydraulic stabiliser extensions during opening.
- Do NOT place hands or feet under the stabiliser feet.

USER MANUAL
HC1151
WARNINGS
A.57845436-01 11/18
subject to change without notice
- Do NOT place lower limbs between the stabiliser leg and vehicle and do NOT place hands near
the stabiliser beams during retraction.
- Do NOT perform maintenance when the crane is moving or when the power take-off is enabled.
Do NOT touch the crane when it is moving.
- Abide by safety distances indicated in EN 349 and make sure all others do the same.
A.2.3 CUTTING HAZARD
Residual hazard associated with movement of booms and any connecting rods. A residual cutting
hazard exists for the upper limbs between moving parts associated with the booms, base and
telescopic components.
WARNINGS
- When the crane is in operation do NOT place upper limbs between the boom joints, near
connecting rods or in the area where stabiliser rods are retracted into the base. Do NOT insert
fingers, feet or limbs inside openings on moving parts.
- Do NOT stand between the base and booms during crane closing.

USER MANUAL
HC1151
WARNINGS
A.67845436-01 11/18
subject to change without notice
A.2.4 IMPACT HAZARD
Residual hazard associated with
impact with the crane boom during opening/closing
impact with the moving load
impact with the stabilisers
impact caused by release of the load
WARNINGS
- Take care not to bump against moving parts on the crane. Specifically, do NOT bang your head
on the boom during working operations.
- Take great care not to bump against the suspended load. The load must always be moved under
safe conditions away from potential hazards and obstacles, as specified in this manual.
- Always check that the load lifting components (hook, shackle, slings, chains) are in perfect
condition. Do NOT exceed the maximum load indicated on the plate. Check that the load is
properly secured to prevent accidental falling. Do NOT stand under the load.
- Take care to prevent impact between stabilizer legs and things/persons during rotation.