HIAB X-Duo 044 User manual
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
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.
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 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
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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
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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
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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
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 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:
9
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.
1
10
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!
This manual suits for next models
4
Table of contents
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