Jonsered 1250RZ User manual

Jonsered 1250RZ
-1500RZ safety+R
CE
Operator's Manual GB
This operator's manual is an Original Instruction and applies to cranes with serial number from:
BF1250RZ0001, BJ1500RZ0001
2020-07

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]
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.

Table of Contents
1. Introduction ......................................................................................... 5
1.1. This Operator's Manual is intended for operators of this crane. ................... 5
1.1.1. Description of Jonsered 1250RZ and Jonsered 1500RZ with
safety+R ............................................................................... 6
1.2. The Machinery Directive 2006/42/EC ................................................. 7
1.2.1. Identification of this crane .................................................... 7
1.3. Indications in the Operator’s Manual .................................................. 7
2. Structure and parts of the crane ............................................................... 10
2.1. Main groups ............................................................................ 10
2.2. Crane base with column and slewing system ...................................... 10
2.3. Boom system and add-on lifting accessories ...................................... 11
2.4. Stabiliser system ...................................................................... 11
2.5. Operating system - hydraulic components ......................................... 11
2.6. LHV Load holding valves ............................................................. 12
2.7. Premium high seat [option] ........................................................... 12
2.7.1. Controlbox ................................................................... 12
3. Safety precautions and warnings .............................................................. 14
3.1. Use of lifting equipment ............................................................... 14
3.2. Use of dismountable cranes .......................................................... 15
3.3. Signs on the crane .................................................................... 15
3.4. Maximum load ......................................................................... 16
3.5. Operating conditions .................................................................. 18
3.6. Maximum load moment ............................................................... 19
3.7. Wind speeds ........................................................................... 20
3.8. Signals when using a crane .......................................................... 20
3.9. Use of the crane ....................................................................... 24
4. The Safety+R .................................................................................... 32
4.1. System Safety+R ...................................................................... 32
4.2. How the Safety+R system works .................................................... 32
4.3. Graphical user interface (ECU) ...................................................... 33
4.4. Stop button ............................................................................. 36
5. Starting crane operation ........................................................................ 37
5.1. Starting operations .................................................................... 37
5.2. Set the stabiliser system .............................................................. 37
5.2.1. Stabiliser system and ground conditions ................................. 37
5.2.2. Stabiliser deployment monitoring .......................................... 38
5.3. Operate the boom system ............................................................ 40
6. During operation ................................................................................. 41
6.1. Operate the crane ..................................................................... 41
6.2. Operation from the high seat ......................................................... 42
6.3. Features ................................................................................ 43
6.3.1. Over load protection (OLP) ................................................ 44
6.3.2. Overturn protection (OTP) .................................................. 45
6.3.3. Error in the system .......................................................... 45
7. Ending crane operation ......................................................................... 46
7.1. Placing the stabiliser system in the transport position ............................ 47
7.2. Stabiliser system and boom system ................................................. 48
Jonsered 1250RZ -1500RZ safety+R CE 3

7.3. TWI Transport warning interface ..................................................... 49
8. Maintenance and Service ....................................................................... 50
8.1. Service .................................................................................. 50
8.2. Warranty ................................................................................ 51
8.3. Follow the maintenance instructions! ............................................... 51
8.3.1. Daily inspection .............................................................. 52
8.3.2. Weekly inspection and maintenance ...................................... 53
8.3.3. Daily inspection .............................................................. 54
8.3.4. Weekly inspection and maintenance ...................................... 56
8.3.5. Monthly inspection and maintenance ..................................... 56
8.3.6. Twice a year maintenance ................................................. 57
8.3.7. Annual maintenance ........................................................ 57
8.3.8. Adjust the chain in the telescope .......................................... 58
8.4. Lubrication .............................................................................. 59
8.4.1. Lubrication ................................................................... 60
8.4.2. Lubrication of the upper column bearing ................................. 60
8.5. Hydraulics .............................................................................. 61
8.5.1. Crane base: checking the oil level/oil change ............................ 61
8.5.2. Replacing the cartridge in return oil filter ................................. 62
8.5.3. Replacing the cartridge in high pressure filter ........................... 63
8.5.4. Checking the oil tank level ................................................. 64
8.5.5. Changing the hydraulic oil .................................................. 64
8.5.6. Bleeding air from the hydraulic system ................................... 66
8.6. Troubleshooting ........................................................................ 66
8.6.1. Main fuses- Column box .................................................... 66
8.6.2. Faults in the crane .......................................................... 67
9. Decommissioning ................................................................................ 68
9.1. Decommissioning a crane ............................................................ 68
4 Jonsered 1250RZ -1500RZ safety+R 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
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 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.
Introduction
Jonsered 1250RZ -1500RZ safety+R CE 5

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.
1.1.1. Description of Jonsered 1250RZ and Jonsered 1500RZ with safety
+R
Safety+R recycling crane is intended for heavy-duty recycling applications: handling of scrap metal,
building debris, waste, recycled material and bulky filling materials with a grapple, clamshell bucket
or polyp grab. Hook is not allowed!
These cranes are compact, fully hydraulically operated loader crane and fulfils the European
Machinery Directive requirements specified in the standard EN12999. Stress history class S3 in
accordance with EN 13001-1
The crane type and the manufacturer are marked on the manufacturer plate.
NOTE
The exact technical information for your crane is shown in the Technical Data.
Introduction
6 Jonsered 1250RZ -1500RZ safety+R CE

1.2. The Machinery Directive 2006/42/EC
• The Declaration of Conformity, delivered with the crane
contains (1):
• Business name and full address where the crane is
manufactured (2):
Factory addresses:
Hiab Cranes S.L.U. Pol. Ind. Malpica, calle E, 86 50016
Zaragoza, Spain
Cargotec Poland Sp. z o. o. Ul. Metalowa 2, 73-102
Stargard, Poland
• Description and identification of the loader crane (3):
Mark
Type: see chapter Identification of the crane.
Serial number
Manufact. year
Declaration of which provisions the loader 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
1.2.1. Identification of this crane
Description and identification of the loader crane:
Mark: ...................
Type: ...................
Serial number: ............................
Manufact. year: ............................
1.3. Indications in the Operator’s Manual
What must you do and not do?
The following indications are used in the Operator’s Manual:
DANGER
Danger to life for yourself or to bystanders.
Follow the instructions carefully!
Declaration of conformity with the
Machinery Directive 2006/42/EC
We ………………….
…………………
…………….
hereby declares that the loader crane:
Mark: …………..
Type:
Serial number:
……………..
.………………
Manufact. year: ………….
complies with the provisions of the machinery
directive 2006/42/EC;
also complies with the provisions of the
directive on electromagnetic compatibility
2004/108/EC as amended.
Technical file in accordance with Directive
2006/42/EC, Annex VII A is compiled by:
Name: …………………….
Address: ..............................
…………………….
This declaration is drawned up by:
Name …………………….
Position ……………………..
➀
➁
➂
➃
➄
xxxxxxxxxxx
xxxxxxxxxxx
Type: ..................................
Serial number: .................................
Manufact. year: .....................
Mark: .....................
Introduction
Jonsered 1250RZ -1500RZ safety+R CE 7

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.
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.
1
Introduction
8 Jonsered 1250RZ -1500RZ safety+R CE

• 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 1250RZ -1500RZ safety+R CE 9

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) Stabiliser system
(4) Operating system (depends on the configuration)
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
ཱིི཰ཱ
Structure and parts of the crane
10 Jonsered 1250RZ -1500RZ safety+R CE

2.3. Boom system and add-on lifting accessories
The boom system consists of the following
components:
(1) 1st boom
(2) 2nd boom
(3) Hydraulic extensions
The length of the hydraulic extension depends on the type
of crane.
(4) Grapple
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) Switch
• (5) 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
⑤
Structure and parts of the crane
Jonsered 1250RZ -1500RZ safety+R CE 11

2.6. LHV Load holding valves
The crane is equipped with load-holding valves as a safety
device. After a crane movement they hold the crane in
position, also in the unlikely event of a burst hose.
If there is a leak or a component fractures, such as a pipe,
hose or a coupling, the load-holding valves will stop the
booms from collapsing down, even when the hydraulic
system is switched off, and you operate a particular crane
function.
To operate a hydraulic cylinder equiped with a load holding
valve, an opening pressure is required.
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.
2.7.1. Controlbox
NOTE
The order of the buttons may differ, some are options. Please follow the symbol on
the button.
Structure and parts of the crane
12 Jonsered 1250RZ -1500RZ safety+R CE

(1) Display
(2) Stop button
(3) Right stabiliser leg in/out
(4) Left stabiliser leg in/out
(5) Stabiliser extensions in/out
(6) Bunks
(7) Console
(8) Stand by/Extra [option]
(9)Work lights [option]
(10) Seat heater [option]
(11) Scale [option]
(12) RPM+ RPM- [option]
(13) Engine start/stop [option]
(14) Extra [option]
(15) Button to be used when operating the stabiliser system
EXTRA
EXTRA
STOP ②345
7
68
910 11
12 13 14
15
Structure and parts of the crane
Jonsered 1250RZ -1500RZ safety+R CE 13

3. Safety precautions and warnings
3.1. Use of lifting equipment
DANGER
• Only use lifting accessories that are
suitable for your crane. Contact a HIAB
service workshop.
• Never attempt to install add-on lifting
accessories yourself!
• Add-on lifting accessories may only be
installed by an authorised HIAB service
workshop.
• When using lifting accessories, follow the
instructions supplied with the equipment!
• Watch out for hazards!
• Never try to adjust lifting accessories when
you are working on the crane!
After the lifting accessories have been fitted:
1. Check that the lifting accessories are
securely fixed.
2. Only after this you should use your
crane.
Type
Max.
pressureMPa
Max.
loadkg
Weight MPa
SerialNo.
Manuf.
year
CargotecEstoniaAS
Linda20
EE-20309NARVAESTONIA
211946
WARNING
• Clean the couplings, when connecting and disconnecting lifting accessories. Dirt
can damage the hydraulic system.
• Take care that your fingers are not trapped.
Safety precautions and warnings
14 Jonsered 1250RZ -1500RZ safety+R CE

3.2. Use of dismountable cranes
DANGER
• Ensure that there are no unauthorized persons in the immediate vicinity of the
crane. When mount/dismount the crane to the vehicle people can suffer fatal
crushing injuries!
• After setting up:
Check that the crane is properly locked!
Dismounting the crane
1. Make sure that the ground where the crane will be parked is firm.
2. Fully extend and set the stabilisers to ground.
3. Park the crane straight backward with a piece of wood underneath the crane tip to prevent
damage.
4. Disconnect the power take off to ensure that the hydraulic system is without pressure.
5. Disconnect the crane from the chassis.
6. Slowly drive the vehicle away from the crane.
WARNING
Take care when mounting/dismounting the crane on/off the vehicle.
Roughly handling can seriously damage the crane or the vehicle.
3.3. Signs on the crane
SAE 80W/90
MAX
MIN
TÄYTÄ TÄSTÄ
PÅFYLLNING
FILLING
EINFÜLLUNG
REMPLISSAGE
A
C
B E D
F
Cargotec Sweden AB
SE-824 83 HUDIKSVALL SWEDEN
TYPE
SERIAL NO
MANUF. YEAR
xxx-xxxx
xxxxxxxxxx
MAX
X X X X X X,X m
kgXXXX
XXXXXXXXXXXXXXXXXXXX
XXXXXXX XXXX XX
xxxxxxx
XXX kN
Safety precautions and warnings
Jonsered 1250RZ -1500RZ safety+R CE 15

NOTE
The signs may vary depending on country. Always make sure that you comply with
the statutory requirements of the country in which you use the crane.
3.4. Maximum load
Lifting capacity
Your crane has a certain lifting capacity, expressed in kNm or tm. This lifting capacity is also known
as the load moment. The lifting capacity is: the payload multiplied by the outreach in metres that
the crane can operate at different positions. The lifting capacity of your crane determines the
maximum load your crane may lift within its working zone. However take careful note; the greater
the operating radius of the crane, the lower the lifting capacity will be because of the weight of the
boom system itself. The load plate and the load diagram on your crane show the maximum loads
you may lift in the operating reach of your crane.
DANGER
• Overloading could result in damage to the crane or in the worst case, personal
injury or death
• Never increase a hanging load, since that may cause a load holding valve to
open and/or the vehicle to turn over.
• Never use the crane with the OLP system switched off.
NOTE
The extra weight of the lifting accessories has to be added to the load. Thus, with
lifting accessories the load you can lift is less heavy.
Load plate
You will find the load plate next to the main control station.
On the plate is the maximum weight that you may lift at a
given reach, with the 1st boom in the optimum position. In
chapter Technical Data in this manual you will find these
values for your crane.
DANGER
Never exceed the maximum weight on the load plate.
Optimum lifting position
The weight that your crane can lift will be determined by:
• Stability of your crane on the vehicle.
Safety precautions and warnings
16 Jonsered 1250RZ -1500RZ safety+R CE

• Stabiliser extensions position and legs pressure to the ground.
• The outreach at which you are working and boom position.
WARNING
During testing crane (LHV, OLP, VSL
etc.) follow the optimal boom
position of your crane as shown on
the picture:
• Position the 1st boom into an
angle of 20 degrees,
• Position the 2nd boom into an
angle of 40 degrees.
40º
20º
For Z-type cranes avoid situations
when 1st and 2nd booms are in one
line. In this particular position, the
2nd boom might be easily
overloaded when extending the
outreach of the crane and cause
uncontrolled fall load on the ground.
Load diagram
You can find the load diagram in the enclosed technical
data and it shows the maximum load your crane may lift in
the entire working zone.
The load curves show the maximum load that may be lifted
at a given reach and height. For a given maximum load, the
possible working zone is to the left of the load curve. The
lifting capacity for some cranes is limited in the high lifting
area.
Safety precautions and warnings
Jonsered 1250RZ -1500RZ safety+R CE 17

WARNING
Care must be taken when handling loads in
the high lifting area, so the load/tool does not
come into contact with the boom system.
3.5. Operating conditions
You may only use the crane under the following conditions:
• In the open air, or in spaces with sufficient ventilation.
• With a mean wind velocity less than 13.3 m/sec (approx. 29.7 mph). See the wind speed table.
DANGER
• If you use the crane in a confined space you could suffocate from the exhaust
gases from the vehicle.
• Never use the crane in a high wind or storm. When the mean wind velocity
exceeds 13.3 m/sec (approx. 29.7 mph) the crane will behave unpredictably.
Never use the crane during a thunderstorm.
•Never use the crane at temperatures below -40°C (-40°F), as the steel's
properties deteriorate below this temperature.
WARNING
• At temperatures below 0°C (32°F):
Do not touch the operating levers during
the first few minutes.
• When starting in cold weather, the wear on
the hydraulic system is greater than at
normal working temperatures.
To get a good function of the crane, it should
be started as follows:
• Engage the power take-off at low rpm.
• Allow the system to idle for a few minutes.
• Operate stabiliser legs up and down for
one minute, in order to warm up the oil.
Safety precautions and warnings
18 Jonsered 1250RZ -1500RZ safety+R CE

3.6. Maximum load moment
If your crane has reached the maximum load moment
(lifting capacity), the OLP gives a warning and locks any
crane movement that will increase the load moment. This is
known as an OLP situation.
If a OLP situation takes place, then the following
movements are locked: First boom up Second boom up
Second boom extension out
• 1st boom up
• 2nd boom up
• 2nd extension boom out
If the OLP situation takes place and movements are locked , you must decreased the maximum
load moment before you can continue loading. Operate the crane movements in the following order
until the OLP situation is over and all movements unlocked.
1. 2nd extension in.
2. 2nd boom down
3. 1st boom down down
If all functions are still blocked, it is possible to temporarily
release OLP and operate appropriate crane movements to
correct the overload situation, de chapter "during operation"
DANGER
Only use the OLP release to get the crane out of a locked position. Never use the
OLP release to overload the crane deliberately!
Safety precautions and warnings
Jonsered 1250RZ -1500RZ safety+R CE 19

3.7. Wind speeds
Wind speed averaged over 10 minutes at a height of 10 m
Wind
Force
Above flat ground Characteristics
m/s Wind type
0 0.0 - 0.2 Calm Calm, smoke rises vertically or nearly
vertically
1
2
0.3 - 1.5
1.6 - 3.3
Slight breeze Wind direction recognisable from smoke
plumes, the wind begins to be noticeable on
the face; leaves begin to rustle and weather
vanes can start to move.
3
4
3.4 - 5.4
5.5 - 7.9
Moderate wind Leaves and twigs in continuous movement,
small branches begin to move. Dust and
paper begin to move over the ground.
5 8.0 - 10.7
Fairly strong
wind
Small leaved branches make swaying
movements; crested waves form on lakes
and canals.
6 10.8 - 13.8
Strong wind Large branches move; you can hear the
wind whistling in telephone wires; umbrellas
can only be held with difficulty.
7 13.9 - 17.1 Severe wind Entire trees move; the wind causes difficulty
when you walk into it.
8 17.2 - 20.7 Stormy wind Twigs break off, walking is difficult.
9 20.8 - 24.4
Storm Causes superficial damage to buildings
(chimney pots, roof-tiles, and TV antennae
are blown off).
10 24.5 - 28.4 Severe storm Uprooted trees; considerable damage to
buildings etc. (occurs infrequently on land).
11 28.5 - 32.6 Very severe
storm
Causes extensive damage (occurs very infre
quently on land).
12 > 32.6 Hurricane
3.8. Signals when using a crane
DANGER
• If it is not possible to see the load and the entire working area clearly the crane
operator is obliged to follow the instructions and signals given by a qualified
person qualified.
• The country-specific regulations for crane operator signals are to be used.
Signals in this manual give a number of standard signals that can be used.
Safety precautions and warnings
20 Jonsered 1250RZ -1500RZ safety+R CE