HIAB Hooklift Multilift XR S Series Operating instructions

MULTILIFT XR S
4/2019
Hooklift XR2S / XR3S / XR5S
USER AND MAINTENANCE MANUAL
110817116/US

This manual is a translation from the original operating instructions
compiled in Finnish.

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Contents
MULTILIFT XR2S, XR3S AND XR5S HOOKLIFT........................................................... 5
Preface............................................................................................................................. 6
Main components ............................................................................................................. 7
Control unit ....................................................................................................................... 8
Safety instructions and safety rules........................................................................... 10
Safety during use - general ............................................................................................ 10
Requirements for the working area ground condition..................................................... 12
Working area .................................................................................................................. 13
Safety instructions and maintenance.............................................................................. 15
Container........................................................................................................................ 15
Loading and unloading of a container ............................................................................ 17
Tipping............................................................................................................................ 21
Before driving away........................................................................................................ 23
Safety facilities of the XR hooklift equipment ................................................................. 24
Use................................................................................................................................. 25
Loading a container........................................................................................................ 27
Tipping a container ......................................................................................................... 33
Lowering the tipping device............................................................................................ 35
Unloading a container..................................................................................................... 37
Loading of rear heavy container..................................................................................... 43
Unloading of a rear heavy container............................................................................... 43
Loading of a front heavy container ................................................................................. 43
Technical specications .............................................................................................. 44
Main components ........................................................................................................... 48
Construction ................................................................................................................... 49
Hydraulic system ............................................................................................................ 50
Equipment..................................................................................................................... 52

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Hook models................................................................................................................... 52
Locking mechanisms of the hook ................................................................................... 53
Electric system ............................................................................................................... 57
Additional equipments................................................................................................. 58
Additional hydraulics....................................................................................................... 58
MAINTENANCE............................................................................................................. 60
Service table................................................................................................................... 64
Hydraulics service .......................................................................................................... 66
Safety functions.............................................................................................................. 72
General inspection.......................................................................................................... 74
Welding........................................................................................................................... 75
Electric system ............................................................................................................... 75
Repairing Damaged Paint Surface................................................................................. 76
Emergency operation ..................................................................................................... 77
LUBRICATION ............................................................................................................... 78
Periodical Service........................................................................................................... 80
Service Card................................................................................................................... 81
WARRANTY CONDITIONS ........................................................................................... 82
To the buyer.................................................................................................................... 82
Owner’s Warranty........................................................................................................... 83
DELIVERY CARD .......................................................................................................... 89

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XR2S XR3S XR5S
MULTILIFT XR2S, XR3S AND XR5S
HOOKLIFT
User Manual
This manual concerns the MULTILIFT XR2S, XR3S and XR5S hooklift equipment.
Information about the equipment.
Type of system:
Serial number:
Date of commissioning:
Owner
Your Multilift dealer
Service workshop:

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XR - S 110817102 11 2004/03
Koukkulaite XR - S Käyttöohjekirja
Rakenne
Yleistä
XR-S koukkulaite on suunniteltu standardin mukaisten vaihtokuormatilojen
käsittelyyn. Lava voidaan vetää päälle, kipata ja laskea maahan.
Koukkulaitteen varusteisiin kuuluu mekaaninen lavalukitus ja lisävarusteena
hydraulinen lavalukitus.Koukkulaitteen liikkeet aikaansaadaan
hydraulisylintereillä. Sylintereiden hallinta tapahtuu sähköohjatuilla
suuntaventtiileillä.
Koukkurunko työntyy ulos välirungosta niin, että lava voidaan vetää eteen ja
työntää taakse laitteen rungolla päällevedon ja maahanlaskun aikana.
Koukkurungon vaakasiirtoliikkeen tekee hydraulisylinteri.
Välirunkoa liikutellaan pääsylinterillä, joka on kiinnitetty apurunkoon.
Kippauksen aikana välirunko on lukittu takarunkoon mekaanisella kippilukolla.
Kuva 5. Koukkulaite
Rakenne
MULTILIFT XR5S hooklift equipment
Cargotec Finland Oy
Multilift
Raisio
Finland
2019
Note!
Cargotec Finland Oy reserves the right to change specications, equipment, operating and
maintenance instructions without prior notice.
Preface
The XR S hooklift equipment is designed for manipulations with swap truck bodies under
the standard SFS 4417 only. The hooklift equipment complies with the requirements of the
EU Machinery Directive and has the CE marking. The seller of a machine entity (chassis
and hooklift equipment) shall be responsible for the conformity of the whole entity. The
installation tter of the equipment shall provide to the Customer the Declaration of Conformity
for the completed installation. The environment protection aspects, e.g. as regards the
noise levels produced by the equipment and the recyclability of parts, have been also taken
into consideration in the design of the XR S hooklift equipment. Proper use of the hooklift
equipment and regular maintenance will ensure durability and reliability of the equipment.
We recommend keeping this User Manual together with the vehicle instruction manual in
the driver’s cabin, easily accessible at hand.
Use only genuine spare parts from Multilift.
The XR S hooklift equipment is a high-quality Finnish product manufactured by Multilift
and marketed by Multilift sales network.
Multilift reserves all rights relating to this User Manual.
Multilift reserves the right to change the construction of the equipment without any special
notice after the publication of this User Manual.

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Koukkulaite XR - S Käyttöohjekirja
XR - S 110817102 12 2004/03
Mekaaninen rakenne
Koukkulaite on rakennettu apurungolle, joka on kiinnitetty ajoneuvon runkoon
kiinnityslevyillä.Takarunko on laakeroitu apurungon takapäähän takarullien
akseleilla.Takarullat ohjaavat ja keventävät vaihtokuormatilan kulkua
päällevedon ja maahanlaskun aikana.
Laitteessa on takarunkoon asennettu mekaaniset lavalukkokoukut ja
mahdollisesti lisävarusteena saatava hydraulinen lavalukko.Takarungon
etupuolella on siihen akselilla kiinnitetty välirunko.Kippauksen aikana
takarungon ja välirungon nivel jäykistetään kippilukon avulla.Välirungossa on
koukkurunko koukkuineen.Välirungon ja koukkurungon väliin on sijoitettu
liukupalat. Ne keventävät koukkurungon liukumista raskaankin kuormituksen
alaisena.
Kuva 6. Mekaaninen rakenne
Rakenne
Takarulla
Apurunko
Kippilukko
Välirunko
Mekaaniset lavalukot
Koukkurunko ja
koukku
Takarunko
Hydrauliset lavalukot
(lisävaruste)
Ohjausventtiili
Öljysäiliö
1
2
3
4
5
6
7
8
9
10
Main components
Due to continuous product development some picture details may look di󰀨erent when
compared to the actual device.
1. Gripping hook and hook arm
2. Middle frame
3. Body locking, mechanical
4. Body locking, hydraulic (optional)
5. Rear rollers
6. Rear frame
7. Sub frame
8. Oil tank
9. Control valve
10. Tipping lock

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3a
3b
2a
2b
1
3a
3b
2a
2b 4
55
6a
6b
3a
3b
2a
2b
10
11
7
4
5
8 9
8 9
Control unit
Control unit Control unit Control unit
basic version basic version with options XR S equipment with
all options

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Control unit components and basic functions
Ref. Component or function
1Control unit cable
2Rocker switch MAIN CYLINDERS
a main cylinders forward
b main cylinders backward
3Rocker switch HOOK ARM
a hook arm forward
b hook arm backward
4 Button SLOW SPEED
5 Warning light FRAME NOT DOWN
6 Rocker switch HYDRAULIC BODY LOCKS
a hydraulic body locks closed
b hydraulic body locks open
7 Warning light HYDRAULIC BODY LOCKS NOT CLOSED
8 Rocker switch ADDITIONAL HYDRAULICS 1 FUNCTION (option)
9 Rocker switch ADDITIONAL HYDRAULICS 2 FUNCTION (option)
10 Rocker switch PTO / PUMP ON - OFF
11 Rocker switch NIGHT SILENCE ON - OFF

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Safety instructions and safety rules
MULTILIFT XR hooklift equipment was developed for the loading, unloading, tipping
and transporting of removable containers/bodies on vehicles. All other use of the Multilift
hooklift equipment is strictly forbidden. Multilift accepts no liability whatsoever with regard
to such other use.
The hooklift equipment meets all safety and stability standards that apply at the moment
of its delivery from the factory. Use the hooklift equipment only if it is in good condition,
and only for the purpose for which it was designed and in accordance with the instructions
and guidelines specied in this manual.
Cargotec Finland Oy Multilift accepts no liability whatsoever for any loss or damage caused
by the failure to strictly adhere to the safety instructions specied in this manual or due
to carelessness during the operation, adjustment, maintenance or repair of the hooklift
equipment. Depending on the specic working conditions, additional safety instructions may
be required. Contact your Multilift dealer immediately if you have encountered an unsafe
situation with XR hooklift equipment that is not described in this manual.
Safety during use - general
The driver must be familiar with the contents of this manual and should strictly follow the
directions and instructions. He must see to it that his XR hooklift equipment is technically
in perfect condition. Control of the suspension, condition of the tyres, tyre pressures, weak
or poor condition of the container or unsuitable loading of it, are all his responsibility. The
driver must handle the XR equipment with care. For example during loading and unloading
the front wheels of the truck must not be lifted up from the ground.
In the vicinity of the control units there must be no obstacles or loose objects that might
accidentally activate unit´s functions.
If the equipment has not been used for two weeks or longer, all safety functions must be
checked before the equipment is used again.

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Avoid the unnecessary use of the main pressure relief valve. Heating up of the oil reduces
the quality of it and results in shorter life span of retaining rings and gaskets.
In subzero temperatures (<32°F) it is recommended to let the pump idle for around 1 minute
in order for the hydraulic oil to be warmed up.
During the use of the equipment the engine noise will increase due to additional loading.
Noise level will also increase if the container is pulled along the ground during loading or
unloading of it. When the equipment is used carefully and in a sensibly planned manner,
the noise level can be kept lower.
Take care that the truck or the hooklift is not overloaded. Observe the factory data for
the truck with regard to maximum permissible axle load/GVW. See also the axle load
calculations!
Strong winds will have an e󰀨ect on the operation during loading, unloading or tipping of
the container.
If several successive containers switches are performed, the hydraulic oil may
overheat >140ºF (60ºC) making it necessary to install an oil cooler to the system.
When leaving the driving cab for loading, unloading or tipping,
always engage the parking brake.

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Requirements for the working area ground condition
Before you start loading, unloading or tipping using the XR hooklift equipment, you must
inspect the following:
- the ground must be rm and free from potholes into which the truck could move
during operation
· - the ground must not be slippery
- the ground must be level

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! !
! !
6 m
Working area
Load or unload only where there is su󰀩cient space; this also applies to free height. There
must be at least 33 ft (10 m) free space at both sides of the vehicle.
Check the vicinity for possible dangers.
When loading, the container must be placed in line with the driving direction of the truck.
If working in the dark, use working lights shining backwards in addition to the standard
truck lights.
20 ft
(6 m)

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! !
It is the responsibility of the driver to ensure that there are or there will be no other persons
within the danger zone of the working area. It is strictly forbidden for anybody to be close
to the truck or the container.
Tip Mark out the working area, for example, with cones.
Tip Ensure that the warning buzzers are operational
In case of emergency:
Disengage the clutch and the PTO.

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WID
Safety instructions and maintenance
Always follow the maintenance instructions and use only original Multilift spare parts.
See chapter Maintenance.
Container
The demountable body can be a container, tank, gravel body, body for transporting
machinery etc. according to standards (e. g. DIN 30722, SFS 4417, SS 3021 or CHEM).
Check to be sure that the container is suitable for the load to be transported. Generally each
container has a model plate (ID) on which the length and permissible load are specied.
Before picking up the container, check that the hook height (H), tunnel height (T) and the
width (W) correspond with the XR hooklift dimensions and that the notches for the body
locks are in correct positions.
If there is even the slightest doubt of the container dimensions, measure them rst in order
to prevent the equipment and the container from being damaged.
Gripping height (H), tunnel height (T) and width (W) of the container can vary from one
container to another. Note that they are country specic dimensions. If there is doubt about
the origin of the container, the tunnel height and width must be checked in order to ensure
that they are compatible with those of the Multilift equipment.
Country specic standard dimension table of the container is on the next page.

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H
L
T
min. SFS 160 mm / DIN 140 mm
min. SFS 140 mm / SS 180 mm / DIN 150 mm
Gripping height (H), tunnel height (T) and width (W) of the container can vary from one
container to another. Note that they are country specic dimensions. If there is doubt about
the origin of the container, the tunnel height and width must be checked in order to ensure
that they are compatible with those of the XR equipment.
Country specic standard dimension table of the container is on the next page.
If your country is not mentioned on the list, check the matter in your hooklift equipment
technical specications.
The condition of the container must be checked regularly. Especially if you are going to
use a type of container with which you are not familiar. In particular, check the condition
of the locking points and the condition and position of the lifting hook.
The maximum allowed wear of the lifting hook is 10 % from its nominal diameter. Nominal
diameter must be checked with the hooklift equipment supplier.
The longitudinal rails at the bottom of the container are under heady burden. Carry out
daily checks of these components for wear or damage.
If the container is frozen to the ground, do not pull it loose by using the XR hooklift equipment.
Use, for example, a forklift truck.
min. SFS 6.3 in (160 mm) / DIN 5.5 in (140 mm)
min. SFS 5.5 in (140 mm) / SS 7.1 in (180 mm) / DIN 5.9 in (150 mm)

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Loading and unloading of a container
Ensure before loading that the length of the container is suitable for your XR hooklift
equipment
Loading of a balanced container requires special care.
Never load, unload or tip a container when the load is heavier to one side or the ground
is sloping.
! !! !

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Ensure that the load´s centre of gravity is as low as possible and that it is in the middle
of the container and evenly distributed. If the load must be secured, do this when the
container is on the ground.
Ensure before loading or unloading of the container that all the removable equipment are
safely fastened and that the load space tail gate, side doors and the load’s fastening have
been checked.
Reverse the truck as slowly as possible to avoid damaging the container, the load or the
XR hooklift equipment.
If the truck is not in line with the container, position the container in line by lifting the front
end of it approx. 3.9 in (10 cm) and pulling it forward by truck. This will prevent the container
from being pulled outside the rear rollers, and the hooklift and rear lights being damaged.
When moving the container to get it in line with the truck, rst remove all obstacles in front
of the container.
When loading or unloading a container, ensure that the hydraulic body locks are open.
Remember that the maximum permissible speed of the pump = the recommended engine
speed. Let the engine run at idle speed while switching the hydraulic body locks on and
o󰀨. Each movement must begin and end at idle speed of engine and at low speed of the
tipping cylinders. In addition the recommended pump speed (= engine speed) must not
be exceeded.

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When loading and unloading a container, be sure that it is running in line between the
rear rollers.
Stop the movement of the middle frame immediately when the container is on ground. If
the hooklift movement is not stopped in time, the truck rear end will be lifted up from the
ground, which will cause damaging of the container, truck or the hooklift equipment.
Before picking up the container, the gripping bar of the container must be properly inside
the lifting hook. In this way you prevent the container from falling. The situation must be
checked by lifting the container approx. 3.9 in (10 cm) and after that checking physically
and visually that the container gripping bar is inside the lifting hook.

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The operation of the hooklift must take place in the correct sequence, one operation at
the time.
The handbrake of the vehicle must be activated during the loading and unloading operation.
When loading, unloading or tipping a container, check that there are no people too close
to the operation, and check for any possible unusual or disruptive movements or sounds
caused by the container. If you notice anything like this, STOP THE OPERATION, press
the clutch pedal and disengage the PTO. Find out the reason for this carefully. Do not
continue the operation before the cause has been established! Failing to do this could
result damaging the container or the XR equipment. The disruption must be remedied
before the operation is continued.
NEVER LOAD, UNLOAD OR TIP IN DANGEROUS SITUATIONS:
• When the load is heavier to one side of the body
• Illegally heavy load
• Sloping or slippery ground
• Soft or crumbly ground under the truck wheels
• Strong side wind, over 20 m/s [44 mph (70 km/h)]
• Frozen or stuck load
TRUCK PROBLEMS:
• Weak springs on one side
• Poor condition of tyres
Before using the under-run bar, ensure that there is nobody close or under the under-run
bar frame.