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