Jonsered 1250RZ Operator'S Manual Download

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Jonsered 1250RZ -1500RZ R CE

Summary of Contents for 1250RZ

Page 1: ...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 ...

Page 2: ...elf with your crane before you start to use it Help us to improve this manual Please send your comments and suggestions to documentation hiab com 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...

Page 3: ...le 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 stabili...

Page 4: ...st 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 fro...

Page 5: ...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...

Page 6: ... 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 intende...

Page 7: ...ntification 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 h...

Page 8: ...mation 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 Neve...

Page 9: ...er 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 controlle...

Page 10: ... 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 ...

Page 11: ...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 hydrau...

Page 12: ...nder 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...

Page 13: ...nsole 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 3 4 5 7 6 8 9 10 11 12 13 14 15 Structure and parts of the crane Jonsered 1250RZ 1500RZ safety R CE 13 ...

Page 14: ...atch 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 pressure MPa Max load kg Weight MPa Serial No Manuf year Cargotec Estonia AS Linda 20 EE 20309 NARVA ESTONIA 211946 WARNING Clean the couplings when ...

Page 15: ...p 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 FILL...

Page 16: ... 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 ...

Page 17: ... 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 g...

Page 18: ...ocity 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 ...

Page 19: ...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 situati...

Page 20: ... 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 la...

Page 21: ...otion with the hand Stop all crane movements Hold the load in position Raise the open hand with the palm clearly visible and arm at shoulder height Keep the hand still Emergency stop for all movements by the crane Raise the hands and the arms to an oblique angle Safety precautions and warnings Jonsered 1250RZ 1500RZ safety R CE 21 ...

Page 22: ... gear change the reach or turn Change the reach Signal with your hands Sideways movement outwards with both hands Thumbs outwards Sideways movement inwards with both hands Thumbs inwards Turn in the direction indicated Indicate the direction with the hands Open the tool Extend the arms at shoulder height with the palms facing downwards Safety precautions and warnings 22 Jonsered 1250RZ 1500RZ safe...

Page 23: ...xtend both arms at shoulder height with the palms facing upwards Make vertical movements with both arms outstretched Keep the tool in position briefly Raise the hand drooping slightly with the fist clenched Safety precautions and warnings Jonsered 1250RZ 1500RZ safety R CE 23 ...

Page 24: ... as it comes under load is not pushed into the ground Ensure you can see the stabiliser legs and stabiliser extensions when you are operating them Do not lower the stabiliser legs on the edge of an embankment soft shoulder slope etc Lower the stabiliser legs only on to a flat and firm surface DANGER Do not stand in front of the hydraulically operated stabiliser legs when you are operating them Nev...

Page 25: ...placed between the boom tip and the load grapple rotator Separate lifting accessories are connected to the standard load hook slings chains chackles etc Preparation for use WARNING Make sure that there are no unauthorised persons within the operating range of your crane WARNING If a part of the crane comes in contact with an electricity line you will be electrocuted Maintain the following minimum ...

Page 26: ... an insulated conductor Minimum distance to an uninsulated conductor 500 V 0 5 m 2 m 500 40000 V 1 5 m 4 m 40000 V 2 0 m 6 m Voltages are found up to 500 V to buildings 500 40000 V trams trains over 40000V power transmission Safety precautions and warnings 26 Jonsered 1250RZ 1500RZ safety R CE ...

Page 27: ...arfs bracelets Jewellery loose clothes and other hanging items can be caught in some parts of the crane DANGER When you go into or out from the control station use only handles and supports on the crane that were specifically made to help the operator to go into or out from the control station Safety precautions and warnings Jonsered 1250RZ 1500RZ safety R CE 27 ...

Page 28: ...e support plate does not bend under load Do not lower the stabiliser legs on the edge of an embankment soft shoulder slope etc Lower the stabiliser legs only on to a flat surface Slide the stabiliser extension on both sides of the vehicle out completely if possible Then lower the stabiliser legs for support Never operate the stabiliser legs while the crane has a load WARNING Use low force when pla...

Page 29: ...ve you signals See the list of signals Make certain that you and the person assisting you know these signals Pay attention to the safety of the person giving the signals Never move the vehicle if you have a freely suspended load on the crane Never walk or stand under a suspended load During operation never stand below the boom system or load Do not slew the crane nor lift the first boom nor lift t...

Page 30: ...w the stabiliser legs and stabiliser extensions Lock tiltable stabiliser legs and manual operated stabiliser extensions in transport position Check that the locking mechanisms are properly locked Switch off the operating system Disengage the PTO or power supply after work If you drive with the PTO or power supply engaged this will cause serious damage to the PTO gearbox combination DANGER For cran...

Page 31: ... must be switched off Pay attention to the width and height of the crane in the transport position The crane has to stay within the width of the truck Make sure the parked crane can not hit bridges tunnels etc Pay attention to overhead power lines Make sure that no part of the crane ever comes in contact with overhead power lines For further instructions see vehicle s manual s Safety precautions a...

Page 32: ... movements to an electronical control unit ECU The ECU then decides how the crane can be operated and stops reduces prohibited movements speeds according to the following situations Overload situation lifting When the crane approached the prohibited overload a warning is given When the crane reaches the prohibited overload all movements increasing load moment are stopped When the maximum allowed t...

Page 33: ...4 3 Graphical user interface ECU Buttons and indicators 1 Push to go back to main menu 2 Push to go one step back 3 Press to toggle between menu items 4 Menu options 5 Push to select item or to confrm 6 Push to see the current error 7 LED Green light on Stand by mode Red light flashing Communication is lost Red light on Critical error detected in the system Orange light blinking Time for service S...

Page 34: ...ity indicator OLP situation Current base angle OLP OTP release Service indicator OLP OTP release locked High boom warning Menu options To access the menu push the button 3 To select one item push the button 5 OK In the top left of the screen the name of the item currently highlighted Settings hour and lift counters Active errors Options The Safety R 34 Jonsered 1250RZ 1500RZ safety R CE ...

Page 35: ...goes to standby mode Type of current capacity indicator Choose between the single bar or the continuous bar Single Bars 1 bar 10 of capacity Bars 1 8 0 90 green Bars 7 8 55 75 orange Bars 9 10 75 100 red Continuous bars 0 5 of capacity Bars 1 8 0 90 green Bars 9 10 90 100 Button backlights Chose if the buttons should be illuminated or not Color scheme Select bright or dark theme Language Select th...

Page 36: ...ice Number of hours with the crane engaged until next service Use time to next service Number of hours until next service Lifts to service Number of lifts until next service 4 4 Stop button If a dangerous situation occurs press the red stop button on the control box To release the stop button turn it clockwise If you push a stop button this symbol will be shown in the display The Safety R 36 Jonse...

Page 37: ...ulic system might overheat Rpm too low during crane operation the vehicle s engine could stall The maximum rpm may depend upon a governor on your PTO combination Start the system 5 2 Set the stabiliser system To ensure the maximum stability of the vehicle all the stabiliser extensions and legs must be fully extended and set to the ground without lifting the wheels from the ground The display will ...

Page 38: ...ne lifting capacity in relation to the vehicle s stability The ECU reads that the stabiliser extensions are fully extened and and that the stabiliser legs are pressed to the ground When the stabiliser extensions are not fully extended or the stabiliser legs are not pressed to the ground there is a risk of of instability and the crane capacity will be reduced When the stabiliser extensions are full...

Page 39: ...have full control of the movement to avoid risk of crushing 5 Lock the stabiliser leg lock 1 6 Extend the stabiliser extension until the yellow mark is visible If the stabiliser extensions are equipped with a separate lock lock it with the handle 2 7 Operate the stabiliser leg downwards until it is set to the ground Crane with non tiltable stabiliser legs 1 If the stabiliser extensions are equippe...

Page 40: ...olumn 2 Operate the 2nd boom to an upright position 3 4 3 Extend the hydraulic extension until the grapple is feee from the support hook 4 Push the grapple against the ground and straighten the 2nd boom 5 5 Push the second boom against the ground and raise the 1st boom slowly Starting crane operation 40 Jonsered 1250RZ 1500RZ safety R CE ...

Page 41: ...y with the values listed on the load plate do not overload the crane Do not lift a load over yourself or the cab Never drive the cylinders to their extreme positions at full speed Never operate the stabiliser system while the crane is loaded Make sure that the weight of the load and the vehicle does not rest only on the stabiliser system Adjust the stabiliser leg if necessary Do not load from in f...

Page 42: ...ty line 6 2 Operation from the high seat The high seat is equipped for using tools and it is operated by two or four control levers and two foot pedals For safety reasons it is necessary to sit down on the seat to operate the control levers A Slewing B Grapple C 2nd boom D Rotator E Extension F 1st boom Two control levers and two foot pedals 2 2 Four control levers and two foot pedals 4 2 A C B E ...

Page 43: ...ls and functions If delivered SYMBOLS FUNCTIONS SYMBOLS FUNCTIONS Bunks Rotation tool Scale Grapple Grapple saw Cabin Seat heater Console Lights The order of the functions is customized for each crane 6 3 Features The control system provides a large number of features Certain features are standard others are options During operation Jonsered 1250RZ 1500RZ safety R CE 43 ...

Page 44: ...ops all functions that increase the pressure These symbols will fill the display regardless of the menu together with the actual percentage To release OLP If all functions have been blocked it is possible to temporarily release the OLP and operate an appropriate crane function to correct the overload situation Push and hold the button OK on the display while operating load reducing functions the a...

Page 45: ...ted and all load increasing actions will be stopped until the situation is over The arrow in the display will indicate which direction the boom should be operated Release OTP Push and hold the button OK on the display or press the stop button whilst operating load reducing functions These symbols will show you that OTP or POL is released Base tilting OTP 6 3 3 Error in the system Error in the syst...

Page 46: ... boom and the grapple against the ground 2 Raise the 2nd boom 3 4 3 Retract the hydraulic extensions until the grapple is locked in the support 4 Operate the 2nd boom against the 1st boom Ending crane operation 46 Jonsered 1250RZ 1500RZ safety R CE ...

Page 47: ...ort plate The procedure of operating the stabiliser legs differs depending on the type of stabiliser leg Repeat the instructions for the stabiliser extension and leg on the other side of the vehicle For auxiliary stabiliser system option Repeat the process DANGER Always ensure that the stabiliser legs and the stabiliser extensions are in transport position and securely locked before moving the veh...

Page 48: ...e backwards and perform a rotary movement 5 Stop the operation as soon as the stabiliser leg is almost vertical lock the stabiliser leg lock 1 6 If manual operated stabiliser extension unlock the stabiliser extension with the handle 2 and retract the stabiliser extension completely 7 If manual operated stabiliser extension lock the stabiliser extension with the handle 2 7 2 Stabiliser system and b...

Page 49: ...crane height exceeds a predetermined maximum and when the manual operated stabiliser extensions tiltable stabiliser legs are not locked in the transport position The audible warning can be silenced by an acknowledgement button option or by a signal indicating that the parking brake of the vehicle is engaged The vehicle must not be moved 1 Switch the system on and operate the crane into transport p...

Page 50: ...rk on the crane may only be carried out by or in close consultation with a Hiab service workshop Never try to reinstall the crane Only a Hiab Dealer may reinstall the crane Before carrying out any welding on the vehicle Disconnect the power between the vehicle and the crane Contact the vehicle manufacturer After welding on the vehicle Connect the power between the vehicle and the crane Maintenance...

Page 51: ... not help contact a Hiab service workshop 5 Small leak on a line or hose Determine if you can still park the crane If you can park the crane and go to a Hiab service workshop If you cannot contact a Hiab service workshop 6 In all other cases contact a Hiab service workshop 8 2 Warranty Hiab only provides a warranty if The Warranty Terms and Conditions specified in the Service Warranty Manual are f...

Page 52: ... temperature 50 C Use Max pressure 140 bar Minimum distance between nozzle and the surface 40 cm Never use a high pressure jet cleaner on electronic parts plastic components signs bearings control valves cylinders or the oil tank Only the cranes surface may be cleaned with a high pressure jet cleaner 8 3 1 Daily inspection Stop buttons and stop functions Use the crane and its safety system to make...

Page 53: ...steps passageways and the seat cab Check the fastening of the seat Hydraulic pump Check the fastenings of the hydraulic pump Hose connections Check that the hoses lines connectors cylinders and valves are tight Suction hose Tighten the suction hose connectors if necessary Hydraulic system Bleed air from the hydraulic system Air must be bled from the hydraulic system if the system has been under ma...

Page 54: ... bearings and bushings are undamaged and working properly Stop buttons Check that the Stop buttons are undamaged and working properly Seat Check the fastening of the seat Electronic components Check that these are in good condition Check that the booms do not lower by themselves At rated capacity at maximum hydraulic outreach check that the booms do not lower by themselves Maximum allowed boom sin...

Page 55: ...des and the attachment points for the add on equipment Maintain all add on equipment auxiliary equipment etc according to the instructions supplied with it Oil tank level To check the level in the oil tank Place the vehicle on level ground with the crane in transport position If necessary top up Base oil level Check the oil level in the base If necessary top up Maintenance and Service Jonsered 125...

Page 56: ... use or the controls are slow or inaccurate Bearings and joints Lubricate the base bearing cylinder bearings control lever joints boom system bearings cardan shaft Boom extension and the stabiliser beam Use spray vaseline or chain oil to lubricate the surface of the second boom and extension Use spray vaseline to lubricate the surface of the stabiliser beam Levers Lubricate the levers with a greas...

Page 57: ...and or hydraulic extension Chain in extensions Check the condition and adjust the telescope chain if necessary Grapple Lubricate the grapple with a grease gun according to the operator s manual for your grapple 8 3 6 Twice a year maintenance Take the crane at least twice per year to a Hiab service workshop for inspection and maintenance Carry out the following maintenance Oil tank Remove condensed...

Page 58: ... can adjust the clearance of the extensions 1 or 2 depending on crane type by adding shims underneath the slide pads Crane base Change the oil in the crane base 8 3 8 Adjust the chain in the telescope ཱ ི ཱི ུ ཱུ ྲྀ 1 second boom 2 chain tensioner 3 roller 4 chain tensioner 5 extension 1 6 roller 7 extension 2 2 3 1 2 3 1 Maintenance and Service 58 Jonsered 1250RZ 1500RZ safety R CE ...

Page 59: ...xtend the extensions Slightly retract the extensions 2 to 5 cm to loosen the top chain Leave the 2nd boom in the air to avoid the top chain from tighten 5 Tighten the top chain with the adjustment screw The correct tension is achieved when it is possible to move the chain vertically about 1 5 to 3 cm from its center by hand 6 Check the chain adjustments by extending and retracting the extensions a...

Page 60: ...bricates the upper column bearing while another is slewing the crane Take care that the person lubricating the bearing does not come into contact or get crushed by the crane If you are lubricating the upper column bearing without help Lubricate the upper bearing with a little grease Slew the crane a little Again lubricate with a little grease Repeat until the column has been slewed round completel...

Page 61: ...th transmission oil of type MIL L 2105C or API GL 5 viscosity SAE 80W 90 Changing oil in the slewing housing Change the oil in the slewing house yearly 1 Use a container with sufficient capacity to receive the oil Drain off the oil through the drain plug 2 Refill through the hole for the measuring stick with transmission oil of type MIL L 2105C or API GL 5 viscosity SAE 80W 90 3 Slew the crane aft...

Page 62: ...ressure 2 Clean the immediate surrounding area of the filter 3 Remove the cover 4 Remove the filter cartridge with attached filter housing by using the handle 5 Examine the surface of the filter cartridge for dirt residue and larger particles these can indicate damage to the components 6 Examine the filter housing for any possible mechanical damage 7 Replace the filter cartridge with a new one 8 R...

Page 63: ... a suitable container and clean or dispose of it in accordance with environmental regulations 5 Remove the filter cartridge Examine the surface of the cartridge for dirt residue and larger particles these can indicate damage to the components 6 Clean the filter housing 7 Examine the filter housing and head segment especially sealing surfaces and thread for mechanical damage 8 Always replace the O ...

Page 64: ...eye and hand protection must be worn while carrying out this operation and if there is a risk for inhalation of oil mist a mask as well Inhalation of oil mist Contact a doctor Skin contact Remove polluted clothing wash with soap and water In the event of high pressure injection of the product see a doctor without delay Eye contact Rinse eyes with plenty of water see a doctor if irritation persists...

Page 65: ...iciency of the hydraulic system The naming of the oil in the table below 32 46 or 68 tells the viscosity of that oil at 40 C reference temperature Viscosity of oil at 40 C Temperature range 32 25 C to 75 C 46 15 C to 90 C 68 5 C to 90 C The recommended viscosity during normal working conditions is between 16 and 40cSt Hiab strongly recommend an oil working temperature below 70 C If necessary consi...

Page 66: ...st twice If your crane has a continuous slewing system slew at least two complete rotations 5 Slowly raise and lower the 1st and the 2nd boom to its end position at least twice 6 If the crane is equipped with JIB slowly raise and lower the JIB at least twice with main boom system pointing downwards and upwards 7 Slowly extend and retract the boom extensions to their end position at least twice a I...

Page 67: ...ns are still locked Unlock the extensions Hydraulic fault Go to a HIAB service workshop The slewing movements are irregular or cause abnormal noises Insufficient oil in the hydraulic system Top up the oil tank Insufficient oil in the gear box Top up the oil in the gear box to the required level Bearing assemblies and pinion are not properly lubricated Lubricate the bearing while slewing Bearing as...

Page 68: ...terials can be recycled Follow the regulations of the local authorities Oil and grease must not be spilled on to the ground or released into the environment Drain the oil from hydraulic cylinders valves and hoses Sort the waste Deliver the metal parts for recycling for reuse as raw material These are load bearing structures manufactured from steel or cast iron hydraulic cylinders and lines drained...

Page 69: ...s small plastic and rubber parts Hazardous waste is delivered to a collection point for hazardous waste oils hydraulic oil transmission oil from the slewing system solid lubricants greases from the joints and journal bearings other waste containing oils and greases hydraulic oil filters Decommissioning Jonsered 1250RZ 1500RZ safety R CE 69 ...

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