Jonsered 1188S CE User manual

Jonsered 1188S CE
Operator's Manual GB
This operator’s manual is an Original Instruction and applies for cranes from serial number:
BJ1188S00000
2019-05

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]

Table of Contents
1. Introduction ......................................................................................... 7
1.1. This Operator's Manual is intended for operators of this crane. ................... 7
1.1.1. Cleanliness certificate ........................................................ 8
1.1.2. The Machinery Directive 2006/42/EC ....................................... 9
1.1.3. Description of Jonsered 1188S .............................................. 9
1.2. Indications in the Operator’s Manual .................................................. 9
1.3. Identification of this crane ............................................................ 12
2. Structure and parts of the crane ............................................................... 13
2.1. Main groups ............................................................................ 13
2.2. Crane base with column and slewing system ...................................... 13
2.3. Boom system and add-on lifting accessories ...................................... 14
2.4. Stabiliser system ...................................................................... 14
2.5. Operating system - hydraulic components ......................................... 14
2.6. Buttons on the control panel [option] ................................................ 15
2.7. Premium high seat [option] ........................................................... 15
2.8. Cabin [option] .......................................................................... 16
2.8.1. Control panel in the cabin C912 ........................................... 16
2.8.2. Control panel in the Hi-Cab ................................................ 17
2.8.3. Fuses in the cabin Hi-Cab .................................................. 18
2.8.4. Fuses in the cabin C912 .................................................... 18
2.9. Main control valve ..................................................................... 19
2.10. Stabiliser control valve .............................................................. 19
3. Safety precautions and warnings .............................................................. 21
3.1. Operating conditions .................................................................. 21
3.2. Wind speeds ........................................................................... 22
3.3. Noise declaration ...................................................................... 22
3.4. Signs on the crane .................................................................... 23
3.5. Maximum load ......................................................................... 23
3.6. Signals when using a crane .......................................................... 24
3.7. Use of the crane ....................................................................... 28
3.7.1. Use of lifting equipment .................................................... 34
3.7.2. Use of dismountable cranes ............................................... 35
4. The CE system [option] ......................................................................... 37
4.1. How the CE system works ........................................................... 37
4.2. Components in the CE System ...................................................... 37
4.3. Buttons and indicating lights on the interface ...................................... 38
5. Manual control system [option] ................................................................. 40
5.1. Operation from the high seat ......................................................... 40
5.2. Manual operation from cabin ......................................................... 41
6. HPC [option] ...................................................................................... 42
7. The control system TimberTronics [option] ................................................... 43
7.1. The TimberTronics control system .................................................. 43
7.2. Components in the TimberTronics system ......................................... 43
7.3. Display .................................................................................. 44
8. The control system Multidrive2 [option] ....................................................... 51
8.1. The control system Multidrive2 ...................................................... 51
8.2. Components in the Multidrive2 System ............................................. 51
Jonsered 1188S CE 3

8.3. Multidrive2 control levers and display ............................................... 51
8.4. Buttons and indicator lights on the PDF ............................................ 54
9. Starting crane operation ........................................................................ 56
9.1. Starting operations .................................................................... 56
9.2. Attach the crane to the vehicle ....................................................... 56
9.3. Electric tiltable seat [option] .......................................................... 57
9.4. Extend stabiliser extensions and set stabiliser legs ............................... 58
9.4.1. Stabiliser system and ground conditions ................................. 59
10. During operation ................................................................................ 61
10.1. Operate the crane .................................................................... 61
10.2. Slope control [option] ................................................................ 62
10.3. Adjust the speed of each function for TimberTronic control system ............ 62
11. Ending crane operation ........................................................................ 63
11.1. Placing the stabiliser system in transport position ................................ 63
11.2. Electric tiltable seat [option] ......................................................... 64
11.3. Ending use ............................................................................ 65
11.3.1. For cabins [Option] ......................................................... 66
11.4. Warning interface (TWI) ............................................................. 67
11.5. Remove the crane from the vehicle (console mounted) ......................... 67
11.6. Emergency operation of the dump valve .......................................... 68
12. Maintenance and Service ..................................................................... 69
12.1. Warranty .............................................................................. 69
12.2. Service ................................................................................ 69
12.3. Follow the maintenance instructions! .............................................. 70
12.3.1. Daily inspection ............................................................ 71
12.3.2. Additional daily inspection for the cabin (if installed) .................. 72
12.3.3. Weekly inspection and maintenance .................................... 72
12.3.4. Additional weekly inspection and maintenance for the cabin (if
installed) ............................................................................. 73
12.3.5. Monthly inspection and maintenance .................................... 73
12.3.6. Additional monthly inspection and maintenance for the cabin (if
installed) ............................................................................. 74
12.3.7. Twice a year maintenance ................................................ 75
12.3.8. Annual maintenance ....................................................... 75
12.3.9. Additional annual maintenance for the cabin (if installed) ............. 76
12.4. Lubrication ............................................................................ 76
12.4.1. Lubrication .................................................................. 77
12.4.2. Lubrication of the upper column bearing ................................ 77
12.4.3. Lubrication of ball joints in cabin ......................................... 78
12.4.4. Clean and grease the spring cups. ...................................... 78
12.5. Adjust the lateral clearance of the boom and/or hydraulic extension .......... 79
12.6. Adjust the chain in the telescope ................................................... 79
12.7. Cabin [option] ......................................................................... 80
12.7.1. Adjust the slide pads in the cabin ........................................ 80
12.7.2. Tightening of screws and bolts in cabin ................................. 80
12.7.3. Windshield wiper fluid ..................................................... 81
12.7.4. Change wiper blade ....................................................... 81
12.7.5. Replace leds on the control panel ....................................... 82
12.7.6. Change the air filter ........................................................ 82
12.8. Hydraulics ............................................................................. 83
4 Jonsered 1188S CE

12.8.1. Crane base: checking the oil level/oil change .......................... 83
12.8.2. Bleeding air from the hydraulic system .................................. 83
12.8.3. Replacing the cartridge in return oil filter ................................ 84
12.8.4. Replacing the cartridge in high pressure filter .......................... 85
12.8.5. Checking the oil tank level ................................................ 86
12.8.6. Changing the hydraulic oil ................................................ 86
12.9. Troubleshooting ...................................................................... 88
12.9.1. Faults in the crane ......................................................... 88
12.9.2. Faults on the CE device ................................................... 89
13. Diesel heater [Option] .......................................................................... 91
13.1. Diesel heater [option] ................................................................ 91
14. Technical Data .................................................................................. 94
14.1. Load plate table ...................................................................... 94
15. Decommissioning .............................................................................. 95
15.1. Decommissioning a crane .......................................................... 95
Jonsered 1188S CE 5

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Jonsered 1188S CE

1. Introduction
1.1. This Operator's Manual is intended for operators of this
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
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 equipment 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.
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.
Introduction
Jonsered 1188S CE 7

1.1.1. Cleanliness certificate
All Hiab equipment has been tested and certified at the
factory according to the Hiab Standard C250.52 that
defines the Cleanliness Requirements for Hydraulic
Systems. This means that they fulfil the cleanliness class
20/18/14 measured by the ISO 4406 standard.
All hydraulic functions have been individually tested and
fully comply with the defined requirements.
NOTE
Hiab shall at all times have the right to:
• install, maintain and dismantle remote diagnostics tools or similar sensor-based
connectivity capabilities (“Connectivity”) in and from the Equipment; and
• access, send, receive, collect, store and use any and all information and data
gathered through the Connectivity, including but not limited to, information
concerning efficiency, availability, downtime, operation, operating environment,
movement, condition, logon, location and similar information relating to the
Equipment (the “Information”). Such Information may be used for optimizing the
Equipment, or any related equipment or services as well as for Hiab's internal
business and/or operating purposes. Hiab shall be responsible for complying
with applicable laws and regulations related to such Information.
The customer/user shall not in any way remove, disable, or interfere with the
Connectivity or the Information. Any intellectual property rights or other right and
title in and to the Connectivity features and the Information and all their further
developments shall at all times be and remain the exclusive property of Hiab.
Introduction
8 Jonsered 1188S CE

1.1.2. The Machinery Directive 2006/42/EC
• Business name and full address where the crane is
manufactured (2):
Factory addresses:
Cargotec Sweden AB Hiab SE-824 83 Hudiksvall
Sweden
Cargotec Poland Sp. z o. o. Ul. Metalowa 2, 73-110
Stargard Szczecinski, Poland
• The Declaration of Conformity, delivered with the crane
contains (1):
• Description and identification of the timber handling
crane (3):
Mark
Type: see chapter Identification of the timber handling
crane.
Serial number
Manufact. year
Declaration of which provisions the timber handling crane
fulfils.
• Name and address of the person authorised to compile
the technical file (4):
Name
Address
• Identity and signature of the person who drawn up the
declaration (5):
Name
Position
Date and Signature
1.1.3. Description of Jonsered 1188S
The Jonsered 1188S is designed for loading cut-to-length timber with a grapple, Usually installed
on a timber truck, either in the rear or behind the cab, it is not intended for hook duty .
The Jonsered 1188S is available in many versions with a wide range of accessories, and fulfills the
requirements of the European Machinery Directive as specified by the standard EN12999.
On the serial number plate, you can find information on the crane type and on the manufacturer.
NOTE
The exact technical information for your crane is shown in "Technical Data".
1.2. Indications in the Operator’s Manual
What must you do and not do?
The following indications are used in the Operator’s Manual:
Declaration of conformity with the
Machinery Directive 2006/42/EC
We ............................................
............................................
.....................................
hereby declares that the timber handling crane:
Mark: .....................
Type: .....................
Serial number: ....................
Manufact.year: ....................
• complies with the provisions of the machinery directive
2006/42/EC;
• also complies with the provinsions of the directive on electro-
magnetic compability 2004/108/EC as amended;
• complies with the harmonised standard
EN 12999:2011/A1:2012.
Technical file in accordance with Directive 2006/42/EC, Annex
VII A is compiled by:
Name: .........................................
Adress: ..........................................
...........................................
This declaration is drawn up by:
Name: .................................
Position:.................................
XXXXXXX .................
…………………………………………………………………
཰ཱཱིིུ
Introduction
Jonsered 1188S CE 9

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.
Symbol for reference to a component in an illustration.
(1) Refers 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.
Introduction
10 Jonsered 1188S CE

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 instruction 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
immediately, 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
operation as described in this manual.
• You should therefore study the Operating Manual for the add-on equipment
carefully, before you use the crane.
• Take particular note when placing the crane in to or out of transport position.
Introduction
Jonsered 1188S CE 11

1.3. Identification of this crane
Description and identification of the crane:
Mark: ...................
Type: ...................
Serial number: ............................
Manufact. year: ............................
Type: ..................................
Serial number: .................................
Manufact. year: .....................
Mark: .....................
Introduction
12 Jonsered 1188S CE

2. Structure and parts of the crane
2.1. Main groups
The crane consists of the following main groups:
(1) Crane base with column and slewing system
(2) Boom system
(3) Operating system (depends on the configuration)
(4) Stabiliser system
2.2. Crane base with column and slewing system
The crane base, column and the slewing system consist of the following
components:
• Crane base
with stabiliser beam, column bearings and three-point
bridge.
• Column
is fitted to the crane base and turns in an upper and a
lower bearing.
• Slewing system
④①②③
Structure and parts of the crane
Jonsered 1188S CE 13

2.3. Boom system and add-on lifting accessories
The boom system consists of the following
components:
• 1st boom (1)
• 2nd boom (2)
• Hydraulic extensions (3)
The length of the hydraulic extension depends on the
type of crane.
Add-on lifting accessorie is placed between the boom tip
and the load.
2.4. Stabiliser system
All our cranes are equipped with two stabiliser extensions
and two stabiliser legs. Auxiliary stabiliser systems may be
needed for heavy cranes.
(1) Stabiliser beam. The stabiliser beam is a part of the
crane base.
(2) Stabiliser extensions.
(3) Stabiliser locking device.
(4) Stabiliser leg.
2.5. Operating system - hydraulic components
The operating system consists of the following hydraulic components:
• oil tank
• hydraulic pump
• oil cooler [option on some cranes]
• main control valve
• stabiliser control valve
• hydraulic hoses and lines
• actuators:
first boom cylinder
second boom cylinder
extension cylinder/s
slewing cylinders
• return filter/oil tank
• pressure filter
③①②
④①②③
Structure and parts of the crane
14 Jonsered 1188S CE

2.6. Buttons on the control panel [option]
Control the stabiliser system from the high seat [option]
The crane and the stabiliser system can be operated from
the high seat.
(1) Stabiliser leg, left
(2) Stabiliser leg, right
(3) Stabiliser extension out/in
(4) Console or optional function
(5) Bunk movement
(6) Lights
(7) Load weighing device [option] / activation of the main
control [HPC option]
(8) Seat heat [option]
(9) Button to be used together with (1), (2), (3)
(10) Optional button
DANGER
Take care not to put your foot on the pedals when taking place in the high seat.
Unintentional crane movements can occur.
Before leaving the high seat, switch off the system from the control panel,
deactivate the main control (HPC).
2.7. Premium high seat [option]
(1) Handle to adjust seat forward/backward
(2) Seat belt
(3) Handle to adjust height of the seat
(4) Locking device for seat tilting
(5) Handle to adjust armrest
DANGER
For cranes with joysticks and HPC, always deactivate HPC before leaving the high
seat.
DANGER
Take care not to put your foot on the pedals when taking place in the high seat.
Unintentional crane movements can occur.
10
Structure and parts of the crane
Jonsered 1188S CE 15

2.8. Cabin [option]
(1) Front door
(2) Protective curtain
(3) Work lights
(4) Side door
(5) Warning light
(6) Service hatch
(7) Heater/cooler
(8) Control panel
2.8.1. Control panel in the cabin C912
NOTE
The top on the control panel depends on the selected heating/cooling system. For
diesel heather, see section diesel heather.
(1) Electric Control (Stand by)
(2) PTO
(3) Stabiliser extension in/out
(4) Left stabiliser leg in/out
(5) Extra button
(6) Cabin up/down
(7) Work light, crane boom
(8) Work light, roof
(9) Windshield washer
(10) Wiper
(11) Extra button
(12) Blind plug
(13) Switch for diesel heater [option]
(14) Right stabiliser leg in/out
(15) Stop button
(16) Extra button
(17) Over load warning
(18) Warning light
(19) Button to be used when operating the stabiliser system
(20) 12V outlet
(21) Seat heater
཰ཱཱཱིིུུྲྀཷ
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
17
18
19
20
21
22
23
24 25 26
Structure and parts of the crane
16 Jonsered 1188S CE

(22) Blind plug
(23) Heater [option]
(24) Fan [option]
(25) AC [option]
(26) Air mix [option]
2.8.2. Control panel in the Hi-Cab
NOTE
The top on the control panel depends on the selected heating/cooling system. For
diesel heater, see section diesel.
(1) Electric Control (Stand by)
(2) PTO
(3) Blind plug
(4) Left stabiliser leg in/out
(5) Stabiliser extension in/out
(6) Right stabiliser leg in/out
(7) Blind plug
(8) Cabin up/down
(9) Extra button
(10) Extra button
(11) Blind plug
(12) Work light, roof
(13) Work light, crane boom
(14) Warning light
(15) Blind plug
(16) Wiper
(17) Windshield washer
(18) Seat heater
(19) Blind plug
(20) Activate Webasto remote [option]
(21) Switch between AC/Heather
(22) Blind plug
(23) Blind plug
(24) Switch for diesel heater [option]
(25) Stop button
(26)Over load warning
1 2 3
6 7
4 5
8 9
10 11
12 13
14 15
16 17
18 19
20 21
22 23
24
25
24
26
27
28
29
30
31
33
32
Structure and parts of the crane
Jonsered 1188S CE 17

(27) Button to be used when operating the stabiliser system
(28)12 V outlet [option]
(29) Heather [option]
(30) Fan [option]
(31) AC [Option]
(32) Airmix
(33) Activate AC
2.8.3. Fuses in the cabin Hi-Cab
F1 15A Diesel heater, cooler
compressor
F1
F2
F3
F4
F5
F6
F7
F8
F9
F10
F11
F12
F2 10A Work light, outside cabin
(15A 12V/Xenon)
F3 10A Work light, boom system
(15A 12V/Xenon)
F4 10A Wiper, washer, work light
inside cabin
F5 10A Control panel
F6 10A CE box Diesel heater
F7 10A Weigher
F8 10A Lighter
F9 10A Cooler
F10 20A AC
F11 10A Spare fuse
F12 10A Spare fuse
2.8.4. Fuses in the cabin C912
F1 40A Diesel heater, cooler compressor
F1
F2
F3
F4
F5
F6
F7
F8
F9
F10
F11
F12
F2 10A Work light, outside cabin (15A 12V/Xeon)
F3 10A Work light, boomsystem (15A 12V/Xeon)
F4 10A Wiper, washer, work light inside cabin
F5 10A Control panel
F6 10A CE box Diesel heater
F7 10A Scale
F8 10A Lighter
F9 10A Cooler
Structure and parts of the crane
18 Jonsered 1188S CE

F10 10A Cooler compressor
F11 10A Spare fuse
F12 10A Spare fuse
2.9. Main control valve
Near each lever there is a sticker with a symbol. The symbol illustrates the function of the lever.
Always operate the lever according to the symbol sign.
The speed of a function corresponds to the extent of the lever movement, regardless of the load
and other functions, as long as the oil flow is sufficient. When the oil flow is insufficient, one or more
functions might reduce their speed.
2.10. Stabiliser control valve
The crane is equipped with a stabiliser control valve. The valve can be operated with the levers on
the valve and from the high seat/cabin [option]
There are several types of stabiliser control valves. Always
operate the lever according to the function on the symbol
sign.
The symbol is shown either on the lever knob or on a
separate sign placed vertical/horizontal next to the lever.
•Stabiliser extension (1) out/in
•Stabiliser leg (2) upward/downward
The stop button affects the oil supply to this valve.
➀
➁
➀➁
Structure and parts of the crane
Jonsered 1188S CE 19

Operate the stabiliser extensions and stabiliser legs.
From the high seat:
Press and hold the button (3) at the same time.
From the cabin:
Press and hold the button (4) at the same time.
3
4
Structure and parts of the crane
20 Jonsered 1188S CE