maxilift M50 Series User manual

Mod. M50
Code MD.0.136GB Rev 0Edition 03/07
USE AND MAINTENANCE MANUALUSE AND MAINTENANCE MANUAL
USE AND MAINTENANCE MANUALUSE AND MAINTENANCE MANUAL
USE AND MAINTENANCE MANUAL

Fill in the space below with the required crane identification data.
Codefilling example: M50.2H ELH
SERIAL NUMBER: ......................
MANUFACTURING YEAR: ...................
Mark the box regarding the accessories supplied with the crane
ACCESSORIES SUPPLIED WITH THE CRANE
Description YES NO
Electrical winch
Manualwinch
Stabilizer
Back load attachment
Quick fitting kit
PRELIMINARYINFORMATION
Operator’sandMaintenanceManual ofMAXILIFT M50 truck loader.
Manualcode: MD.0.136 GB
This manual is valid starting from serial no: ....................
Manufacturer:NEXT HYDRAULICS S.r.l.
ViaMediterraneo6,Boretto(RE)-ITALY
Inthis manualthe word “Manufacturer” isreferred to“NEXT HYDRAULICS S.r.l.”.
Listof documentationsupplied along with the loader:
¾Operator’sand Maintenance Manual(for the enduser)
¾InstallationManual (forthe installerand the end user)
ATTENTION
Always carefully read this manual before operating the loader. Most of the accidents occurred during
operations are caused by omission of elementary precautions and non fulfilment of the safety instructions.
Many accidents can be avoided when their causes are well known and relevant adequate
countermeasures are previously taken.
M50 2 H E L H
.
M50 2
.

INDEX
1 FOREWORD -------------------------------------------------------------------------------------------- Page--1
1.1 Remarks ------------------------------------------------------------------------------------------------“ ----- 1
2 HOW TO CONSULT THE MANUAL------------------------------------------------------------------- “----- 1
2.1 Instructions ------------------------------------------------------------------------------------------------“ ----- 1
3 CRANEIDENTIFICATION-------------------------------------------------------------------------------- “----- 2
3.1 Identification data--------------------------------------------------------------------------------------------“ ----- 2
3.3.1 Nameplate description ------------------------------------------------------------------------------------“ ----- 2
3.2 Main cranecomponents identification------------------------------------------------------------------“ ----- 2
3.3 Crane composition ------------------------------------------------------------------------------------------“ ----- 3
3.4 Accessories ------------------------------------------------------------------------------------------------“ ----- 4
3.4.1 Winch ------------------------------------------------------------------------------------------------“ ----- 4
3.4.2 Stabilizers ------------------------------------------------------------------------------------------------“ ----- 4
4 COMMISSIONING----------------------------------------------------------------------------------------- “ ----- 5
4.1 Check list before the first commissioning -------------------------------------------------------------“ -----5
4.2 Daily check list ----------------------------------------------------------------------------------------------“ ----- 5
4.3 CE Certification ----------------------------------------------------------------------------------------------“ ----- 5
5 GENERAL SAFETYRULES ----------------------------------------------------------------------------- “ ----- 5
5.1 Rules concerningpersons---------------------------------------------------------------------------------“ ----- 5
5.2 Rules concerning the crane-------------------------------------------------------------------------------“ -----5
5.3 Rules concerning safety in the traffic -------------------------------------------------------------------“ ----- 6
6 OPERATING INSTRUCTIONS -------------------------------------------------------------------------- “ ----- 7
6.1 Daily check list ----------------------------------------------------------------------------------------------“ ----- 7
6.2 Loaderclassification and properusage ----------------------------------------------------------------“ ----- 7
6.3 Improperusage ----------------------------------------------------------------------------------------------“ ----- 7
6.4 General attentions ------------------------------------------------------------------------------------------“ ----- 7
6.5 Ten basicrules forthe safeloader operator-----------------------------------------------------------“ -----9
6.6 Instructions for use -----------------------------------------------------------------------------------------“ ----- 9
6.6.1 Thrustslewing system -------------------------------------------------------------------------------------“ ---- 10
6.6.2 Crank slewing system -------------------------------------------------------------------------------------“ ---- 10
6.6.3 Hydraulicslewing system ---------------------------------------------------------------------------------“ ---- 11
6.6.4 Boom lifting system by mechanic strut ----------------------------------------------------------------“ ---- 11
6.6.5 Boom lifting system by hydraulic cylinder ------------------------------------------------------------“ ---- 12
6.6.6 Two manualextensions boom system -----------------------------------------------------------------“ ---- 13
6.6.7 Boom system with 1st hydraulic and 2nd manual extensions --------------------------------------“ ---- 14
6.6.8 Hydraulic operating system by hand pump for lifting cylinder ------------------------------------“ ---- 15
6.6.9 Hydraulic operating system by hand pump for lifting and extension cylinders ---------------“ ---- 16
6.6.10 Hydraulic operating system by hand pump for extension cylinder ------------------------------“ ---- 17
6.6.11 Electro-hydraulic operatingsystem bypower unit with one function
for lifting cylinder--------------------------------------------------------------------------------------------“ ---- 17
6.6.12 Electro-hydraulic operating system by power unit with two functions for lifting
and extension cylinders -----------------------------------------------------------------------------------“ ---- 18
6.6.13 Electro-hydraulic operating system by power unit with two functions for slewing
and lifting cylinder -------------------------------------------------------------------------------------------“ ---- 19
6.6.14 Electro-hydraulicoperating systemby powerunit withthree functionsfor slewing,
lifting and extension cylinders----------------------------------------------------------------------------“ ---- 20
- I -
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Tel. +39 - 0522-96 30 08 - Fax +39 - 0522-96 30 39
[email protected]

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- II -
6.7 Accessories -------------------------------------------------------------------------------------------- Page- 21
6.7.1 Electrical winch----------------------------------------------------------------------------------------------“ ---- 21
6.7.2 Manualwinch ------------------------------------------------------------------------------------------------“ ---- 23
6.7.3 Stabilizer kit ------------------------------------------------------------------------------------------------“ ---- 24
6.7.4 Back load attachment--------------------------------------------------------------------------------------“ ---- 24
6.7.5 Quick fitting kit-----------------------------------------------------------------------------------------------“ ---- 25
6.8 Main operatingerrors ---------------------------------------------------------------------------------------“ ---- 26
7 MAINTENANCE ANDCHECKING --------------------------------------------------------------------- “---- 27
7.1 Protection andstorage-------------------------------------------------------------------------------------“ ---- 27
7.1.1 Shortshutdowns --------------------------------------------------------------------------------------------“ ---- 27
7.1.2 Longshutdowns ---------------------------------------------------------------------------------------------“ ---- 27
8 MAINTENANCE -------------------------------------------------------------------------------------------- “---- 27
8.1 Warnings ------------------------------------------------------------------------------------------------“ ---- 27
8.1.1 Environmentalprotection ----------------------------------------------------------------------------------“ ---- 27
8.2 Maintenance prescriptions --------------------------------------------------------------------------------“ ---- 27
8.3 Maintenance schedule -------------------------------------------------------------------------------------“ ---- 29
8.3.1 Check list before a working session --------------------------------------------------------------------“ ---- 29
8.3.2 Quarterlychecking------------------------------------------------------------------------------------------“ ---- 29
8.3.3 Yearly checking----------------------------------------------------------------------------------------------“ ---- 29
8.4 Loaderservicing ---------------------------------------------------------------------------------------------“ ---- 29
8.4.1 Oil levelchecking--------------------------------------------------------------------------------------------“ ---- 30
8.4.2 Oil change ------------------------------------------------------------------------------------------------“ ---- 30
8.4.3 Wear pads checks and replacement -------------------------------------------------------------------“ ---- 30
8.4.4 Worm gear assembly control-----------------------------------------------------------------------------“ ---- 31
8.4.5 Thrustrotation brake control------------------------------------------------------------------------------“ ---- 31
8.5 Electric winchmaintenance ------------------------------------------------------------------------------“ ---- 31
8.6 Greases and oils reference table ------------------------------------------------------------------------“ ---- 32
9 TECHNICALDATA ---------------------------------------------------------------------------------------- “---- 33
9.1 Craneoveralldimensions ----------------------------------------------------------------------------------“ ---- 33
9.2 Stabilizeroveralldimensions -----------------------------------------------------------------------------“ ---- 33
9.3 Load chart tables--------------------------------------------------------------------------------------------“ ---- 34
9.4 Technical specifications -----------------------------------------------------------------------------------“ ---- 34
9.4.1 Technical data table ----------------------------------------------------------------------------------------“ ---- 34
9.4.2 Table ofweightsforforeseencrane versions----------------------------------------------------------“ ---- 35
9.4.3 Accessories weights table --------------------------------------------------------------------------------“ ---- 35
10 WIRINGAND HYDRAULIC DIAGRAMS ------------------------------------------------------------- “---- 35
10.1 Hydraulicdiagram hand pumpfor liftingcylinder-----------------------------------------------------“ ---- 35
10.2 Hydraulicdiagram hand pump+ valve bank forlifting
and extension cylinders -----------------------------------------------------------------------------------“ ---- 36
10.3 Hydraulicdiagram hand pump+ valve bank for extensioncylinder------------------------------“ ---- 36
10.4 Electro-hydraulicdiagram motor pump for liftingcylinder------------------------------------------“ ---- 37
10.5 Electro-hydraulic diagram motorpump for lifting and extensioncylinders---------------------“ ---- 37
10.6 Electro-hydraulic diagram motorpump for slewing andextension cylinder -------------------“ ---- 38
10.7 Electro-hydraulicdiagram motor pumpfor slewing,
lifting and extension cylinders----------------------------------------------------------------------------“ ---- 38
10.8 Electricalwinch wiringdiagram --------------------------------------------------------------------------“ ---- 39

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1 FOREWORD
1.1 Remarks
This manual gives the guidelines for a correct, safe usage of the loader and its rational maintenance. When daily and
constantlyapplied, these guidelinesensurelong service lifewithminimum maintenance costs,high performance ofthe
loaderand good commercial valueafteryears.Moreover,most of thefrequentaccidentsduring operation and servicing
are avoided. Once this manual has been read carefully, keep it in good conditions and quickly available close to the
loader.
ATTENTION
Should some or any part of this manual be not clear, please contact the Manufacturer
NOTE
The table on the back of the front page has to be filled at customer’s care. It contains all the necessary data
required when calling our Technical Service.
Acopyofthismanual is supplied alongwithevery loader. Data,descriptions andpicturesof this manualarenot binding.
TheManufacturerreserves the right tochangeat any time alltheitems,components and parts deemedtobe necessary
forproduct improvement orcommercial or productionneeds..
2 HOW TO CONSULT THE MANUAL
2.1 Instructions
Alwayscarefully read this manual beforeoperating the loader.
The manual must be entirely read, except for chapter 6, whose paragraphs must be compulsorily read up to 6.5
inclusive.Paragraph 6.6 containsthe instructions foruse for allthose units thatmay constitutethe machine, andwhich
are represented in the picture of paragraph 3.3. To simplify reading this last one, it is necessary to determine all the
unitsmakingupone’smachine, and to readonly the concerningsub-paragraphs.Actually,relevant legend includes the
correspondingsub-paragraph beside thenameof every singleunit.
Paragraph 6.7 contains the instructions for use for accessories, among which it is necessary to single out those
provided with one’s machine, in order to read relevant the sub-paragraphs. We suggest to cross all the parts of the
manual that do not apply to one’s loader.
In this manual the following symbols are used:
DANGER
Referred to dangers related to the described activity, when the safety of people is concerned.
ATTENTION
Referred to dangers related to the described activity, mainly when the safety of things is concerned (for
instance, damage of the load or of the loader).
IMPORTANT
Referred to information or integration on loader operation.
NOTE
Used to draw your attention on information or suggestions to make easier the loader usage for the operator.
Thesymbols and marksarecompleted with noticesstating the dangers,theirnature, the avoidanceactions to betaken
and tips to be followed.
!

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- 2 -
3 CRANE IDENTIFICATION
3.1 Identification data
Everyloader is identifiedbyits serial numberandname of themodel written ontheplate riveted onthe column (Pict. 1).
3.1.1 Name plate description
¾Cranemodel
¾Serialnumber
¾Yearofmanufacturing
¾Lifting class
¾Max SWL [kg]
¾Max SWL [lbs]
ATTENTION
It is strictly forbidden to change and/
or erase the data written on the name
plate.
3.2 Main crane components identification
Themaincomponentsofatelescopic
boom crane are (pict. 2):
¾Slewingsupport
¾Column
¾Boom assembly
¾Operatingsystem
Thefull crane structure ispositioned
andslews overthe rotation support,
which is consequently the slewing
system housing.
Thecolumnistheslewingcomponent
on which the most important
articulation fulcrums allowing boom
liftingare located.The boom can be
lifted in two ways:
¾hydraulically, by means of a
liftingcylinder;
¾manually, by keeping it in fixed
position by means of a
mechanical support strut.
The boom assembly is the element
allowingloadrecoveringandhooking.
It is consisting of:
¾boom, on which the articulation
fulcrumsare located;
¾extensions, allowing its in & out
movements(manualor hydraulic
by means of a cylinder);
¾hookattachment.
Pict. 1
Pict. 2
Hook
attachment
Extension
cylinder
Boom
Motorpump Button strip
Lifting
cylinder
1st extension
2nd extension
Mechanical
strut
Braking
devicefor
thrust
rotation
Slewing
support
Controlvalve
bank
Handpump
Hydraulic
slewing
device
Crank
slewing
device

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Finally, the operating system is the hydraulic or electro-hydraulic system transmitting the movement to the actuators
(cylinders). It is consisting of a pump (electric or manual) and control system (button strip or hydraulic valve bank).
In this type of crane the slewing support and column assembly make up the slewing system, which can be of three
types:
¾thrustrotation;
¾crankrotation (operatinga worm screw – wormwheel gear);
¾hydraulic(hydraulic motor operating a wormscrew – worm wheel gear).
3.3 Crane composition
A1 Thrust slewing system (6.6.1)
A2 Crank slewing system (6.6.2)
A3 Hydraulic slewing system (6.6.3)
B1 Boom lifting system by mechanical strut (6.6.4)
B2 Boom lifting system by hydraulic cylinder (6.6.5)
C1 Two manual extensions boom system (6.6.6)
C2 Boom system with 1st hydraulic and 2nd manual extensions (6.6.7)
D1 Hydraulicoperating systemwith handpump for lifting cylinder (6.6.8)
D2 Hydraulicoperating systemwith handpump forlifting andextension cylinders (6.6.9)
D3 Hydraulicoperating systemwith handpump forextension cylinder (6.6.10)
D4 Electro-hydraulicoperating systemby powerunit withsingle functionfor lifting cylinder(6.6.11)
D5 Electro-hydraulicoperating system by powerunitwith two functionsforlifting and extensioncylinders(6.6.12) or
forslewing andlifting cylinder (6.6.13)
D6 Electro-hydraulicoperating system bypowerunit with threefunctions for slewing,lifting and extensioncylinders
(6.6.14)
Pict. 3
A2
Lifting
Boom system
Slewing system
Operatingsystem
A1
C2
C1
B1
B2
D1 D2 D3 D4 D5 D6
A3

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3.4 Accessories
According to crane use, there are accessories whose application is not compulsory, but which are essential in some
cases. These are:
¾Winch (see chap. 6.7.1 for electrical winch and 6.7.2. for the manual winch);
¾Stabilizers (see chap. 6.7.3).
Themerely optionalaccessories are:
¾Back load attachment (see chap. 6.7.4).
¾Quick fitting kit (see chap. 6.7.5).
3.4.1 Winch
The winch is a rope lifting device, which is installed on the crane boom, through proper fastening, and which together
with the transmission, coupling and safety devices, becomes an integral part of it
The winch is an accessory allowing the vertical load handling.
On cranes equipped with mechanic strut, the winch is no longer an accessory, rather an essential component, as it is
theonly available liftingdevice.
On this crane, the winch can be either mechanical or electrical, and relevant instructions are reported respectively in
sub-paragraphs6.7.1 and 6.7.2.
3.4.2 Stabilizers
Thestabilizers areinstalled on the vehicle toincrease stability and prevent overturning.
Thestabilizers are consistingof rodsto whose enda stabilizer legis applied; suchleg is an extendable telescopictube
which lowers and leans on the ground by a plate. Such rods can be either fixed or extendable from a tube fixed on the
vehicle, called main beam; the rod locking in this case is made by means of an automatic hooking device.
The stabilizer’s instructions for use are listed in sub-paragraph 6.7.3.
Pict. 4
Manualwinch Electrical winch Back load attachment
Stabilizer Quick fitting
system

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4 COMMISSIONING
4.1 Check list before the first commissioning
Check that the crane is complete of:
¾CEdeclaration ofconformity of thecrane manufacturer;
¾CEdeclarationof conformity ofthecraneinstalling workshop orself-certificationof installation performed according
toManufacturer’s installationinstructions;
¾Operator’sand maintenance manual;
¾other testing certificates according to Safety Law in force.
4.2 Daily check list
¾Check the existence of oil leaks;
¾Checkthe correctworking of all crane safetydevices (asindicated in relevant paragraph);
¾Check oil level and fill up if necessary;
¾Check the good conditions of hoses and piping;
¾Check the good conditions of the rope.
4.3 CE Certification
Fill in the CE certification document with the required crane identification data.
5 GENERAL SAFETY RULES
5.1 Rules concerning persons
¾Always wear the prescribedpersonal safety devices.
¾Alwayswear approved accident-prevention clothingsuch as: protective helmets,anti-slip shoes, protective gloves,
reflective jackets, breathing apparatus and protective glasses. Consult your employer regarding current safety
regulationsandaccident-preventionequipment.
¾Do not wear rings, wristwatches, jewellery, loose-fitting or hanging clothing such as ties, torn garments, scarves,
unbuttoned jackets or unzipped overalls which could get caught up by parts in motion.
¾Keep quickly and readily available on the truck a first-aid box and a fire extinguisher. The fire extinguisher must
always be kept charged and has to be used according to current regulations.
5.2 Rules concerning the crane
¾The Manufacturer is not liable for accidents occurred when using the crane caused by non fulfilment from the
operator’sside ofcurrent rules,laws andregulations.
¾The regular crane functioning is guaranteed within a temperature range between 0°C and +40°C. If temperature
drops under 0°C, it is essential to replace the oil in the whole circuit by a less viscous one, as indicated in the
suggestedoil table.
¾Carefullyread theOperator’s and maintenancemanual beforecommissioning, using, servicingor doingany thing
onthe loader.
¾Read and follow allsafety instruction platesappliedon theloader before starting up, using, servicing or doing any
thingon theloader.
¾Ifthe crane isprovided with electricaldevices, before operatingtheloader make surethat its voltage(12V) is same
asthe vehicleone.
¾Do not use controls and hoses as handholds: these parts move and cannot provide stable support.
¾The operator’s control desk must always be kept clean from oil, grease, mud and snow to avoid accidents due to
slipperysurfaces.
¾Thesafetyinstruction plates, notices,loadcharts and anyothersticker applied ontheloader must be keptreadable
and in good conditions. If necessary, replace them. The position of these plates is shown in pict. 5.

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5.3 Rules concerning safety in the traffic
¾The machine is an hydraulic loader for lorries and light trucks. The installation on the vehicle must be made in
compliancewith therelevant national lawsand regulations.
¾Whentravelling onroads andpublic sites always respect the relevant national laws andregulations.
DANGER
Before travelling on roads, make sure that the loader is folded in rest position. If the loader is open or lying
on vehicle’s body exceeding the overall dimensions allowed by the highway code, it can hit bridges, electric
power lines or other obstructions.
¾Beforedrivingaway, make sure that the levers andthepinssecuringtheoutrigger’sbeam are fully locked.Accidental
slippingout ofthe outriggerbeam duringtravelling canresult in serious accidents.
¾Special care mustbe takenwhendriving nearbycrossroads, level-crossings and subways.
!
Pict. 5
1010
1010
10
1212
1212
12
22
22
2
11
11
1
66
66
6
44
44
4
55
55
5
33
33
3
88
88
8
99
99
9
MAX Kg200
1414
1414
14
1111
1111
11
12V
1212
1212
12
1313
1313
13
1515
1515
15
1616
1616
16
77
77
7