MotoCrane ULTRA Heavylift User manual
Heavylift Operation Manual v1.0
January, 2020
To minimize risk of serious injury, death or
damage, before using MotoCrane Heavylift,
all drivers and operators must read this
Operation Manual and all on-product labels.
All practices and procedures stated herein are
required for the proper and safe operation of
the Heavylift.
If there are any questions, please contact
MotoCrane Support at
Keep this Operation Manual near your Heavylift
for future reference.
Safety Signal Words
This manual and the safety labels attached to this equipment utilize signal words that
signify safety hazards with different levels of severity. The words are preceded by a
triangle signifying that these are safety related. Below are the words used and the
definitions for these words:
● indicates a hazardous situation which, if not avoided, could result
in death or serious injury or damage
● indicates a hazardous situation which, if not avoided, could result in
minor or moderate injury or damage
● is used to address practices not related to physical injury
The terms IMPORTANT and NOTE are also used to describe ideas for better and more
efficient use of the Heavylift.
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Contents
Safety Signal Words 2
Contents 3
Before the First Drive 4
IMPORTANT PRODUCT AND SAFETY INSTRUCTIONS 5
Safety 5
IMPORTANT: Restricted Use Statement 5
Disclaimer and Limitations of Liability 5
Limited Warranty 6
Intellectual Property 6
Intended Use of Heavylift 7
Parts of the Heavylift 8
Heavylift System Overview 8
Installing Heavylift Isolator Components 9
Installing Heavylift Boom Components 13
Using the Heavylift Turret Shims 15
Installing Heavylift Braces 16
Heavylift Weight Chart 18
Known Hazards 19
Transporting the Heavylift 20
Maintenance 22
Weather & Water 22
Revision History 23
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Before the First Drive
Do the following before using the Heavylift for the first time.
1. Read this Operation Manual
2. Read the Warranty in the Terms of Sale
3. Watch any available video tutorials at www.motocrane.com/support
4. Recommended: Attend MotoCrane Training for in-person demonstration
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IMPORTANT PRODUCT AND SAFETY
INSTRUCTIONS
Safety
The MotoCrane Heavylift is not a toy and can cause serious injury, death or damage if
not used properly. You must exercise caution during use of the Heavylift to ensure a
safe filming environment for everyone. This Operation Manual describes safe operation
and should be read in conjunction with the applicable online training videos or
additional in-person training.
IMPORTANT: Restricted Use Statement
The Heavylift must only be used by trained operators 18 years of age or older. Only
appropriate motor vehicles driven on a closed course with paved or finished surfaces
(for example, asphalt, concrete, or tarmac) or moderate off-road (for example, gravel or
dirt roads) conditions may be used. In addition, the speed and acceleration of the
motor vehicle must not exceed system ratings for MotoCrane products as set forth in
this Operation Manual.
Do not modify or adjust the Heavylift. The Heavylift has been calibrated before it is
shipped to you. No modification or adjustment to the Heavylift is allowed without the
express written approval of MotoCrane, LLC.
Disclaimer and Limitations of Liability
You agree that you are responsible for your own conduct and any content created
while using the Heavylift, and for any consequences thereof. You agree to use this
product only for purposes that are proper and in accordance with local laws,
regulations or other legal requirements.
You also agree:
1. Any part of this disclaimer is subject to change without prior notice. Refer to
www.motocrane.com/support for the latest version.
2. MotoCrane, LLC reserves the right of final interpretation of this disclaimer.
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3. MotoCrane, LLC has no control over the use, setup, assembly, modification or
misuse of the Heavylift, and therefore no liability shall be assumed or accepted by
MotoCrane, LLC for any resulting damage, death, or injury incurred directly or
indirectly from the use of the Heavylift. By the act of use, setup or assembly, the
user accepts all resulting liability.
Limited Warranty
The Heavylift has a limited manufacturer's warranty on parts and assembly. See the
Terms and Conditions of Sale for your Heavylift for a complete description of this
limited warranty. This Limited Warranty is incorporated by reference into this
Operation Manual.
Intellectual Property
MotoCrane™, and are trademarks of MotoCrane, LLC. You may not
use the trademarks of MotoCrane, LLC without express written permission. All rights
reserved.
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Intended Use of Heavylift
Heavylift increases ULTRA’s maximum payload by 10 lbs; from 55lbs to 65lbs. It
strengthens areas of high stress with mechanical braces and reinforcements. The use of
Heavylift does not alter any other specs of ULTRA aside from maximum payload and All
Up Weight (AUW). While Heavylift increases the overall strength of the system, it is not
designed for more aggressive off-road terrain or for payloads in excess of 65lbs.
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Parts of the Heavylift
●1 pc Heavylift Airshock Nose Mount
●1 pc Heavylift Airshock Body Mount
●2 pc Heavylift Isolator Badge
●1 pc Heavylift Vertical Fulcrum Brace
●2 pcs Heavylift Upper Vertical Brace Mount
●2 pcs Heavylift Lower Vertical Brace Mount
●2 pcs Heavylift Lateral Brace
●4 pcs Heavylift Lateral Brace Mount
●3 Heavylift Turret Shims (.030”, .048”, .060” Thickness)
●2 pcs Steel Axle
●4 pcs FHCS M6 x 12mm
●24 pcs SHCS M4 x 25mm
●4 pcs SHCS M6 x 25mm
●2 pcs M6 Shoulder Bolt
●12 pcs SHCS M12 x 22mm
●12 pcs M12 Split Lock Washer
●4 pcs M6 Lock Nut
Heavylift System Overview
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Installing Heavylift Isolator Components
Below is the proper setup sequence of the Heavylift Isolator.
1. Loosen and remove existing M6 fasteners to replace existing Steel Axle with M6
Lock Nut torqued to 8.7Nm.
2. Remove existing Aluminum Roll Damper Axle, and install Steel Axle with M6
Lock Nut torqued to 2.5 Nm. Spacers along the axle should be free to rotate.
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3. Remove 4 X M6 fasteners from Air Shock Nose Mount, and 1 X M6 Lock Nut
from Air Shock Body Mount.
4. Carefully remove the Air Shock Assembly, and separate the air shock from the
Nose Mount by removing the M6 Lock nut and removing the M6 Shoulder Bolt.
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5. Remove 2 X M6 fasteners securing the existing Air Shock Body Mount.
6. Install the new Heavylift Air Shock Body Mount using the provided 4 X M6
fasteners.
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7. Attach the air shock to the new Heavylift Air Shock Nose Mount using the M6
Shoulder Bolt and M6 Lock Nut. Torque M6 Lock Nut to 8.7 N-m.
8. Slide the Heavylift Air Shock Nose Mount into the Isolator, and secure using the
provided M6 fasteners and Heavylift badges. Attach the air shock to the new
Heavylift Air Shock Body Mount using M6 Shoulder Bolt and M6 Lock Nut.
Torque M6 Lock Nut to 8.7 N-m.
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Installing Heavylift Boom Components
1. Install the Heavylift Upper and Lower Vertical Brace mounts to the Middle
boom, with 217mm of distance between the mount and Clip Receiver.
2. Install the Heavylift Lateral Brace mounts to the Middle boom, with 198mm of
distance between the mount and Clip Receiver.
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3. Install the Heavylift Upper and Lower Vertical Brace mounts to the Rear boom,
with 217 mm of distance between the mount and Clip Receiver.
4. Install the Heavylift Lateral Brace mounts to the Rear boom, with 198 mm of
distance between the mount and Clip Receiver.
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Using the Heavylift Turret Shims
The 3 Heavylift Turret shims are designed to create a more secure and exact fit
between the ULTRA Base and Turret. Follow these instructions for installation.
1. Place the Turret onto the Base Pedestal as normal and fasten 2x M12 Fasteners
on ONE side without using the shims.
2. Slide the thickest possible shim into the gap between the Turret and Base
Pedestal on the opposite side before installing the remaining 2x M12 Fasteners.
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Installing Heavylift Braces
1. Assemble the Middle and Rear Booms to the Turret as usual, and attached the
Heavylift Vertical Fulcrum Brace to the Mounts using the supplied M12 Fasteners
and split-lock washers.
Failure to secure the booms first can lead to a weak mounting point and
could cause a mechanical failure in ULTRA. Mounting the Heavylift components before
the booms are secured would cause the Heavylift braces to resist the force of
tightening the boom mounting bolts. Mount Heavylift after booms.
Make sure split lock washers are used.
You should loosen the mounts to make slight adjustments, making sure the
brace is centered, and is not crooked.
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2. Attached the Heavylift Lateral Braces to the Mounts using the supplied M12
Fasteners and split-lock washers.
Make sure split lock washers are used.
You may loosen the mounts to make slight adjustments, making sure the braces
are centered, and are not crooked.
Loose mounts will not support the additional payload and can result in a
failure. Remember to tighten all hardware before use.
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Heavylift Weight Chart
Measure the All-Up Weight (AUW) of the payload then use the chart below to
determine how much counterweight (CW) should first be installed before mounting the
payload, and if any is needed after. “Payload” includes everything hanging from
ULTRA including AVM’s like Tranquilizer, stabilized head, camera and accessories. You
must weigh for accuracy. “Tallying” of weight often leads to balancing error.
The Lift axis is equipped with a fail-safe brake. Failure to observe the
proper counterweighting method will result in excessive imbalance beyond the max
permissible limit, and may cause permanent system damage.
EXTENDED Payload All Up Weight [AUW] vs Counterweight [CW] Pre-load Chart
Payload AUW
CW Pre-load
Empty/No Payload
40lbs/18kg
20lbs/9kg
90lbs CW/41kg, mount Payload
25lbs/11kg
100lbs/45kg CW, mount Payload
30lbs/14kg
115lbs/52kg CW, mount Payload
35lbs/16kg
125lbs/57kg CW, mount Payload
40lbs/18kg
130lbs/59kg CW, mount Payload, Add 10lbs/4.5kg
45lbs/20kg
130lbs/59kg CW, mount Payload, Add 20lbs/9kg
50lbs/22kg
130lbs/59kg CW, mount Payload, Add 35lbs/16kg
55lbs/25kg
130lbs/59kg CW, mount Payload, Add 45lbs/20kg
60lbs/27kg
130lbs/59kg CW, mount Payload, Add 65lbs/30kg
65lbs/30kg
130lbs/59kg CW, mount Payload, Add 80lbs/36kg
NOTE: When using the Fairing Extension (req’d for MoVI XL) subtract Counterweight Pre-load by 10lb.
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Known Hazards
The following list represents a list of known hazards that exist when
operating the Heavylift. This is not exhaustive, but represents some common
hazards to watch out for.
●Heavylift mounting. Make sure the Heavylift is secured and does not shift
around during operation. All fasteners must be tight and secured, as per
the setup instructions.
●Heavylift mounting. Tighten the Heavylift braces AFTER securing the
booms.
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Transporting the Heavylift
The Heavylift Isolator is designed to fit into the existing Isolator case. Heavylift shims
are stored in the air shock pump cut out and the hardware bag is packed under the
PSU.
The Vertical and Lateral Brace Mount for the Rear Boom should always remain installed
onto the Rear Boom.
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