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HIAB 710 Operators Manual

710 Operators Manual

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Dennis Xenos
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3K views74 pages

HIAB 710 Operators Manual

710 Operators Manual

Uploaded by

Dennis Xenos
Copyright
© © All Rights Reserved
We take content rights seriously. If you suspect this is your content, claim it here.
Available Formats
Download as PDF or read online on Scribd
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HIAB 710 Operator's Manual Cargotec, Inc. 307 Broadway Swanton, Ohio 43558 1993 FOREWORD This Operator’s Manual deals with your new crane, Take the time to read it through -it will be well spent. The manual contains a short description of the crane together with instructions on its operation and maintenance. If you wish to ensure long life for your crane, you should carefully carry out all maintenance instructions. However, all servicing, apart from lubrication and minor repairs that you can attend to yourself, should be entrusted to the well-trained personnel of your dealer’s service shop. ‘We reserve the right to introduce, without notice, changes in data, equipment and in the instructions for maintenance and other servicing jobs Table of Contents FOREWORD... Section 1. GENERAL DESCRIPTION GENERAL DESCRIPTION ..... BASE WITH SLEWING SYSTEM. BODY......... BOOM SYSTEM .... HYDRAULIC CYLINDERS ROLLING BASE UNDERCARRIAGE. OIL TANK... SUPPORT LEGS GENERAL DIMENSIONS 710-1 .. GENERAL DIMENSIONS 710-2 RANGE DIAGRAM 710-1 RANGE DIAGRAM 710-2. LOAD DIAGRAM 710-1 LOAD DIAGRAM 710-2 .. TECHNICAL DATA HIAB 710-1 .. TECHNICAL DATA HIAB 710-2 ... Section 2. OPERATING INFORMATION INTRODUCTION. CRANE OWNER RESPONSIBILITY CRANE OPERATOR RESPONSIBILIT" CRANE MAINTENANCE .. OPERATION .. OPERATOR QUALIFICATIONS CONDUCT OF OPERATOR OPERATING PRACTICES OPERATOR & SERVICE PERSONNEL TRAINING .. SAFE WORK PRACTICES OPERATING PROCEDURE: OPERATING THE SUPPORT LEGS . PREPARING THE CRANE FOR OPERATION STARTING UP IN COLD WEATHER | SAFE LOAD HANDLING ... Section 3. ee MAINTENANCE SERVICE ... LUBRICATION . HYDRAULIC SYSTEM ..... ELECTRICAL SYSTEM. CHAIN DRIVE SYSTEM WINCH SYSTEM... REGULAR INSPECTION. PREVENTATIVE SERVICE ... TROUBLE SHOOTING... ROLLING BASE INSTALLATION CRANE SPEED ADJUSTMENT HYDRAULIC SCHEMATIC 5 FUNCTION ELECTRIC w/KILL_ ELECTRICAL SCHEMATIC 5 FUNCTION w/KILL WIRING DIAGRAM 5 FUNCTION W/KILL ....... INNER AND OUTER BOOM CYLINDER REMOVAL WARNING DECAL PLACEMENT .... * HYDRAULIC SCHEMATIC 5 FUNCTION ELECTRIC w/DUMP * ELECTRICAL SCHEMATIC 5 FUNCTION w/DUMP..... * WIRING DIAGRAM 5 FUNCTION w/DUMP ... * HANNAY HOSE REEL BALANCED PRESSURE SWIVEL JOINTS * HANNAY HOSE REEL SPRING REWIND REEL INSTRUCTIONS . * These pages reference wet line applications only ! Section 1. GENERAL DESCRIPTION GENERAL DESCRIPTION ‘The HIAB 710 is a compact, all hydraulic vehicle crane in the 54,000 ft-lb capacity class, specially adapted for hook and attachment service. The crane comes in the following versions: HIAB 710-1 with a hydraulic outreach of 17'S", and HIAB 710-2 with a hydraulic outreach of 23°7" ‘The main crane components are: . Base with slewing system Body Boom system |. Hydraulic cylinders Valve system 5. Support legs Oil tank NoaueeEne ‘Your crane’s type and serial number can be found on the name plate. 1-1 3E WITH SLEWIN( The crane base is in the form of a casting and comprises an upper and a lower body bearing, a slewing system and a three point bridge. ‘The guide pad on the rack consists of a lubrication free bearing. The outrigger-leg beam is bolted to the crane by 8 stud bolts. Base Three-point bridge Outrigger-leg beam Frame fastening Body bearing waynes BODY The body is an all-welded, box design with a cast column welded to its lower end. The body can be easily lifted out of the base once the catch has been released. The catch is locked on the base. 6. Body BOOM SYSTEM ‘The boom system consists of an inner boom, an outer boom and an extension. The extension is single in the case of the -1 version and double telescopic in the case of the -2 version. ‘The outer boom and hydraulic extension are hexagonal sections, and the extensions run on lubrication free adjustable slide pads that bear against two opposing oblique surfaces. This arrangement provides ‘exact guidance of the extension without backlash. Inner boom Outer boom Hydraulic extension Manual extension -1 Manual extension -2 yaene HYDRAULIC CYLINDERS. The hydraulic cylinders are double acting; the extension cylinder for the 710-2 is telescopic in addi- tion. The inner boom and outer boom cylinders are fitted with check valves which lock the booms in the event of a hose failure. Inner boom cylinder Outer boom cylinder Extension cylinder -1 . Extension cylinder -2 vane ROLLING BASE GE The rolling base undercarriage is custom built to fit your trailer, or truck body, I-beam flanges. The crane is secured to the undercarriage by means of 8 high strength mount bolts. ‘The drive motor drives the forward axle by a chain and sprocket. The forward axle drives the rear axle via a chain, Slack can be removed from both chains either by the idler system or by adjusting the torque motor position. Drive side main gripper weldment Idler side main gripper weldment Forward axle Rear axle ‘Axle bearing assembly Drive motor assembly . Fixed idler assembly Adjustable idler assembly |. Mount bolts PRI AWAY OIL TANK In the standard version, the oil tank is mounted beside the loader base. It has internal baffles to prevent foaming. The tank also has a built in return filter, oil level indicator, filling stud with strainer and air filter and a water cock at the bottom of the tank. On the side of the tank there is a plugged connection which could be used as a draining connection, for instance when a winch is mounted. The oil tank volume is about 12 gallons. SUPPORT LEGS ‘The support legs are intended to keep the outfit steady while the crane is in use. The outrigger leg extensions slide on rollers greased in plain bearings, making sure that the extensions are easy to handle. ‘The outrigger extensions are available with a tilting device that allows the legs to rotate in a position that is appropriate for transport. The outriggers are locked in position by means of spring catches applied by hand. CYHIAB 710-1 GENERAL DIMENSIONS ALL OF THE DIMENSIONS SHOWN BELOW ARE + 1/2" GENERAL. INSIONS 710-1 GENERAL DIMENSIONS 710-2 YHIAB 710-2 GENERAL DIMENSIONS ALL_OF THE DIMENSIONS SHOWN BELOW ARE: 1/2" RANGE DIAGRAM 710-1 i RANGE se 7 | DIAGRAM 33° = “CUES pve av| Al 5 \h . \ : LOA RMIAEN 13.2 t tI q nN as ‘7 a { 6.6" | TH T * 7 | rt —4 7 as" AL fi SL wl ALOT 7 32 + Z vt i 7 165 b=. 0 83 68 OF 82 16S RAT mA OT a ers OF Range diagram for hydraulic telescoping extensions Range diagram with manual extensions step 1 — Range diagram with manual extensions step 2 Range diagram with manual extensions step 3 —-——-— Range disgram with manual extensions step 4 1-9 RANGE DIAGRAM 710-2 HIAB 710-2 RANGE I — | OIAGRAM LOAD DIAGRAM 710-1 IGHIAB 710-1 26.4" : Loan | a DIAGRAM 19.8" 3240 tb 16.5" 3970 Ib 13.2" +—t 4890 Ib 99 yh oe | (6080 1b ea . 8820 Ib a 3.3" ZIM 6 a 7720 tb 3.3" 4 6.6" |__| 9.9" 13.2° | 0 3.3' 6.6' 9.9' 13.2° 16.5' 19.8 To the left of the curve the indicated load can be handled with any foader function provided that the positions of the booms are optimized from a force point of view ‘Standard hook attachment --~—— Inner hook attachment, for hook application LOAD DIAGRAM 710-2 YHIAB 710-2 Soe — 29.7" LOAD DIAGRAM 26.4" 231° / 2200 tb 19.8" 2870 (b_ 16.5" | 4410 tb 13.2° v\__t t 5510 tb os : fb en 7160 tb 6.6" + | Ne 33 é o A b | as 66 9s 13.2" | 165" 0 33° 66° 9.9° 13.2'16.5' 19.8' 23.1' 26.4" To the left of the curve the indicated (oad can be handled with any loader function provided that the positions of the booms are optimized from a force point of view ——— Standard hook attachment ------ taner hook attachment, for hook application ;CHNICAL DATA HIAB 710-1 Loader capacity ....... 54,235 ft-lbs Hydraulic outreach... sons ITS" Hydraulic boom extension. 59" Outreach, manual extension 2377", 30°2" essatecasosecnessateennscton 36'1", 41" Lifting height above inst. surface 23°11" 5°11" - 8820 Ibs * 1172" - 4890 Ibs 16°9" - 3240 Ibs 23°0" - 2200 Ibs 29°10". 1190 Ibs 35°" 880 Ibs 40°4" - 710 Ibs Outreach/Lifting capacity Outreach/Lifting capacity, manual extension Oil Flow .. ... 8 gpm Working pressure. 3260 psi Oil in tank. 12 gal Tank volume... 16 gal Sewing angle ais? Height folded, crane os" Width folded... 710" Weights: Loader in standard version without outriggers........- 2100 Ibs Rolling base version complete without outriggers........ 3060 Ibs 180 - 440 Ibs Support leg equipment . . 80 Ibs Oil in tank... * Inner hook attachment TECHNICAL DATA HIAB 710-2 $2,070 ft-Ibs 23°7" 116" 30°2", 3671", 30°8" 29°10" 5’11" - 8530 Ibs * 11°10" - 4410 Ibs 17°9" - 2870 Ibs 22°8" - 2200 Ibs 29°6" - 1190 Ibs 35°5" - 880 Ibs 40'- 710 Ibs Hydraulic boom extension . Outreach, manual extension ing height above inst. surface. Outreach/Lifting capacity Outreach/Lifting capacity, manual extension Oil Flow 8 gpm Working pressure... . 3260 psi Oil in tank. 12 gal Tank volume .. 16 gal Slewing angle . 415° Height folded, crane only . 68" Width folded. Tu" Weights: Loader in standard version without outriggers . 2350 Ibs Rolling base version complete without outriggers .. Support leg equipment il in tank. 3310 Ibs .. 180 - 440 Ibs .. 80 Ibs * Inner hook attachment Section 2, OPERATING INFORMATION INTRODUCTION Safe, efficient crane operation depends upon five basic conditions. These conditions are: (1) the crane and vehicle unit must be properly serviced and maintained; (2) the operator must be competent and thoroughly trained; (3) safe work practices must be observed at all times, (4) load limits must never be exceeded; and (5) control functions must be used in the prescribed, correct operating sequence. It ‘must be stressed that not one of these five requirements can be safely eliminated from the crane operating procedure. CRANE OWNER RESPONSIBILITY ‘The owner of this crane is responsible for proper maintenance and repair of the unit and establishing support documentation of the same. The owner is also obligated to perform the ongoing tasks of selecting only competent operator and service candidates and providing personnel the training neces- sary to assure safe operation of the crane unit. CRANE OPERATOR RESPONSIBILITY ‘The operator, operator trainer, or service person is responsible at all times for the safe transport and use of the crane unit. Safe transport and use includes proper storage, recognition and avoidance of all observable hazards to personnel and property, pre-operation inspection, and operating the crane at all times within load and range restrictions stated in this manual. (CRANE MAINTENANCE The crane should be subject to regular inspections and preventative maintenance procedures as prescribed in Section 3 of this manual, and appropriate records of maintenance must be kept. In addition, any defect which is observed and reported in the course of regular pre-operation inspections should be corrected and recorded before the unit is returned to service. OPERATION 1. Crane operation shall be limited to the following persons: a, qualified operators; . trainees under the direct supervision of a qualified operator; ¢. maintenance and test personnel (when it is necessary in the performance of their duties); d._ inspectors (crane). 2. No one other than the personnel specified in (1.) above shall enter the operating area of a crane with the exception of persons such as oilers, supervisors whose duties require them to 2-1 do so and then only in the performance of their duties and with the knowledge of the operator or other appointed person. OPERATOR QUALIFICATIONS Operators shall be required by the employer to pass a practical operating examination Qualifications shall be limited to the type of equipment for which examined Operators and operator trainees shall meet the following physical qualifications: a. vision of at least 20/30 Snellen in one eye and 20/50 in the other, with or without corrective lenses; b. ability to distinguish colors, regardless of position, if color differentiation is required for operation; cc, adequate hearing, with or without hearing aid, for the specific operation, . Evidence of physical defects or emotional instability which could render a hazard to the ‘operator or others, or which in the opinion of the examiner could interfere with the operator's performance, may be sufficient cause for disqualification, In which cases, specialized clinical or medical judgements and tests may be required. Evidence that an operator is subject to seizures or loss of physical control shall be sufficient reason for disqualification. Specialized medical tests may be required to determine these conditions. . Operators and operator trainees should have normal depth perception, field of vision, reaction time, manual dexterity, coordination, and no tendencies to dizziness or similar undesirable characteristics. In addition to the above listed requirements, the operator shall: a. demonstrate the ability to comprehend and interpret all labels, operator’s manuals, safety codes, and other information pertinent to correct crane operation; possess knowledge of emergency procedures and implementation of same; demonstrate to the employer the ability to operate the specific type of equipment; be familiar with applicable safety regulations; understand responsibility for maintenance requirements of the crane; be thoroughly familiar with the crane and its control functions; understand the operating procedures as outlined by the manufacturer. CONDUCT OF OPERATOR |. The operator shall not engage in any practice which will divert his attention while actually engaged in operating the crane. .. Each operator shall be responsible for those operations under the operator’s direct control. ‘Whenever there is any doubt as to safety, the operator shall consult with the supervisor before handling the loads. The operator should not leave a suspended load unattended unless specific precautions have been instituted and are in place. If there is a warning sign on the switch or engine starting controls, the operator shall not close the switch or start the engine until the warning sign has been removed by the appointed person. mreaos Before closing the switch or starting the engine, the operator shall see that all controls are in the “off” or neutral position and all personnel are in the clear. If power fails during operation, the operator shall: 8, move power controls to “off” or neutral position; . land the suspended load and boom, if practical. ‘The operator shall be familiar with the equipment and its proper care. If adjustments or repairs are necessary, the operator shall report the same promptly to the appointed person, and shall also notify the next operator. All controls shall be tested by the operator at the start of each shift. If any controls do not operate properly, they shall be adjusted or repaired before operations are begun, Stabilizers shall be visible to the operator while extending or setting unless the operator is assisted by a signal person, OPERATING PRACTICES Handling the Load Size of Load a, No crane shall be loaded beyond the rated load except for test purposes. b. The load to be lifted is to be within the rated load of the crane in its existing configuration. c. When loads which are not accurately known are to be lifted, the person responsible for the job shall ascertain that the weight of the load does not exceed the crane rated the load at the radius at which the load is to be lifted. Attaching the load a. The load shall be attached to the hook by means of slings or other devices of sufficient capacity. b. Hoist rope shall not be wrapped around the load, . Moving the Load a. The operator shall determine that: i, the crane is level and, where necessary, the vehicle/carrier is blocked properly; the load is well secured and balanced in the sling of lifting device before itis lifted more than a few inches (mm); iii, means are provided to hold the vehicle stationary while operating the crane. b, Before starting to lift, the hook shall be brought over the load in such a manner as to minimize swinging. ©. During lifting, care shall be taken that: i. there is no sudden acceleration or deceleration of the moving load; oad, boom, or other parts of the crane do not contact any obstruction, 4. Cranes shall not be used for dragging loads sideways. €. Articulating boom cranes are designed and intended for handling materials, They do not ‘meet personnel lift or elevator requirements. Therefore, no lifting, lowering, swinging, or traveling shall be done while a person is on the hook or load. Hook-attached suspended work platforms (baskets) shall not be used. Work platforms (baskets) attached to the boom shall be approved by Cargotec, Inc. £ The operator should avoid carrying loads over people. 8. When the rane is so equipped, the stabilizers shall be fully extended and set. Blocking under stabilizers shall meet the requirements as follows: i, strong enough to prevent crushing; ii, of such thickness, width, and length as to completely support the stabilizer pad. h, Firm footing under all tires, or individual stabilizer pads should be level. Where such a footing is not otherwise supplied, it should be provided by timbers, cribbing, or other structural members to distribute the load so as not to exceed allowable bearing capacity of the underlying material i. In transit, the boom shall be carried in stowed position. j. When rotating the crane, sudden starts and stops shall be avoided. Rotational speed shall be such that the load does not swing out beyond the radius at which it can be controlled. k. The crane shall not be traveled with a load on the hook. 1, No person should be permitted to stand or pass under a suspended load. 4, Stowing Procedure. Follow procedure and sequence when stowing and unstowing the crane, OPERATOR & SERVICE PERSONNEL TRAINING ‘The owner-employer is responsible for providing adequate employee training and training documenta- tion. The training should substantiate that any designated operator or service person assigned to the crane unit has satisfactorily met the performance objectives outlined in “Operator Qualifications.” Training methods and materials are left to the informed discretion of the owner-employer. SAFE WORK PRA¢ ES Safe crane operation requires operator competence, mechanical soundness, and observation of equip- ‘ment load limits at all times. Safety procedures outlined in this section should be carefully read by all associated personnel prior to operation, always observed and periodically reviewed to avoid over- sight. ‘The safety considerations addressed in this section are pre-operation inspection and safe operating practices. Preliminary Safety Inspection - Before operating the crane, always perform the following safety 1, POSITION CRANE VEHICLE: Locate crane unit in a safe work area free from electric power lines or any other obstructions. 2, PERFORM WALK AROUND INSPECTION: Inspect major system components: a. Hydraulic System: Inspect visible hoses, connections, and components for signs of physical breakdown or leakage. b. Mechanical System: Inspect visible mechanical structure for damaged or deformed members, and loose or missing bolts or nuts. c. Electrical System: Inspect visible electrical wiring and components for damage. Make sure system connections are secure and free of conductivity hazards. 2-4 4. Winch-Wire Rope-Hook System: Inspect hook and block for soundness; wire rope eye for secure thimble and clamp connections, wire rope for signs of excessive corrosion, wear, broken wires, stretch, kinking or twisting; sheave alignment; and outer wire rope wrap on drum for evenness. CLEAR TEST AREA: Clear intended test area (extended crane travel field) of all personnel. POWER CRANE SYSTEM: Energize crane unit power supply - PTO or auxiliary engine 5. POSITION OUTRIGGERS: Set outriggers in stabilizing position, making sure the supporting surface provides solid footing. 6. TEST CONTROLS: At slow speed, test all crane control functions. Take care to check return-to-neutral response from both control directions on each manual lever or toggle switch. ae NOTE ‘During the control test, observe system response for any signs of unusual vibration, noise, grinding, or binding. If any of these conditions are observed, STOP the test and make appropriate repairs. 7. TEST WINCH BRAKE: Test the hydraulic brake function by engaging a test load, raising the load six inches above rest position, and allowing the lift control function to idle for 30 seconds. Note any observable down drift of the load. If brake is not functioning, the load will drop. Correct before operation. 8, DE-ENERGIZE EQUIPMENT FOR REPAIRS: When repairs are necessary, always shut down or disconnect system power before making them, 9. CORRECT ALL MALFUNCTIONS: Before any work is performed with the equipment, be sure that all observed defects are corrected. Failure to do so can result in serious personal injury or costly equipment damage, NOTE This pre-operation inspection should be performed before every-use. This inspection does not qualify as an alternative to the regular preventative maintenance inspections as described in Section 3. ‘Range & Load Limits - A maximum range and load capacity chart as shown in Section 1 is posted at the crane operator station. The load-range limits identified on this chart should be read and thor- ‘oughly understood before any payload lifting is carried out. Do not exceed the maximum load for any range, Overloading gives risk to tipping and structural failure of the crane, and poses serious safety hazards. Lift all loads with crane boom, Do not lift load with winch as winch capacity may exceed crane load-range capacity and create an overload condition. WARNING A tipping hazard exists when operating the crane on a slope or across a slope grade. Rated range and load capacities must be restricted to compensate for slope operation and to avoid tipping. 2-5 Work Site Location - The safe, recommended work site location for the crane vehicle is a level, dry, firm paved surface, Unpaved ground should provide solid support for gross vehicle weight and any Toad lifted, and sound outrigger footing, Parking on slopes requires special precautions: ark with the grade - vehicle facing upgrade or downgrade, Use wheel chocks on downgrade side of rear vehicle wheels. Parked at curbside with front facing downgrade - tur front wheels into curb. Parked at curbside with front facing upgrade - turn front wheels away from curb, ‘Avoid parking cross-grade, If cross grade parking is unavoidable, then load lifting capacities must be restricted to reduce tipping risk. See WARNING on previous page. 6. Never park on any grades greater than 6° waene ‘The working field (envelope) of the crane should be as free as possible of overhead obstructions, equipment, and materials which could restrict crane operation. The operator should take note of all objects noted above and limit the crane lifting operation to remain well clear of them. Electric power lines pose special hazards and are specifically addressed in ANSI B30.22-3.3.1-1987. POWER LINE PROXIMITY 1. Except where the electrical distribution and transmission lines have been de-energized and visibly grounded at point of work, or where insulating barriers not a part of, or an attachment to, the crane have been erected to prevent physical contact with the lines, cranes shall be operated so that no part of the crane or load enters into the “danger zone” shown in Figure 2-1. a, For lines rated 50 kV or below, minimum clearance between the lines and any part of the crane or load (including handling appendages) shall be 10 ft (3 m). For higher voltages, see table 1. b. Caution shall be exercised when working near overhead lines having long spans as they tend to move laterally or vertically due to the wind which could breach the safety zone. ¢. In transit with no load and boom lowered the clearance shall be as specified in Table 1. 4. A qualified signal person shall be assigned to observe the clearance and give warning before approaching the above limits. 2. Any overhead wire shall be considered to be an energized line unless and until the person owning, such line or the electrical utility authorities verify that it is not an energized line. 3. Exceptions to this procedure, if approved by the owner of the electrical lines, may be granted by the administrative or regulatory authority if the alternate procedure provides equivalent protection and is set forth in writing. 4, Durable signs shall be installed at the operator's station and on the outside of the crane, warning, that electrocution or serious bodily injury may occur unless a minimum clearance of 10 ft (3 m) is 2-6 maintained between the crane or the load being handled and energized power lines. Greater clearances are required because of higher voltage as stated in (a) above. These signs shall be revised but not removed when local jurisdiction requires greater clearances. Above information is taken from ASME-ANSI B 30.22-1987. This area should be avoided. Danger zone area (see general note).

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