MULTILIFT XR S Operating instructions

MULTILIFT XR S
1/2018
Hooklift XR21S59 CHU
USER AND MAINTENANCE MANUAL
113813003/EN

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Contents
MULTILIFT XR S CHU HOOKLIFT.................................................................................. 5
GENERAL DESCRIPTION .............................................................................................. 6
Main components ............................................................................................................. 7
Control unit ....................................................................................................................... 8
Signal lights of control unit................................................................................................ 9
Control system................................................................................................................ 10
Safety instructions and safety rules........................................................................... 17
Safety during use - general ............................................................................................ 17
Requirements for the working area ground condition..................................................... 20
Working area .................................................................................................................. 21
Flatrack/body.................................................................................................................. 23
Loading and unloading of a atrack/body....................................................................... 25
Tipping............................................................................................................................ 29
Before driving away........................................................................................................ 30
Safety facilities of the XR S hooklift equipment.............................................................. 31
HOOKLIFT OPERATION ............................................................................................... 33
Loading a atrack/body .................................................................................................. 35
Loading a short atrack/body ......................................................................................... 49
Tipping a atrack/body ................................................................................................... 55
Lowering the tipping device............................................................................................ 61
Unloading a atrack/body............................................................................................... 65
Loading of rear heavy atrack/body ............................................................................... 79
Unloading of a rear heavy atrack/body......................................................................... 79
Loading of a front heavy container ................................................................................. 79
Loading a atrack/body onto a trailer or platform ........................................................... 80

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LIFTFRAME USAGE ..................................................................................................... 85
Appropriate ISO container types ................................................................................ 85
Buttons on the stowage control unit ............................................................................... 87
Fetching the liftframe with the XR21S hook, moving it and locking it to the stowage .... 89
Moving the liftframe onto the XR21S equipment’s hook............................................... 100
Before gripping and loading the ISO container............................................................. 110
Loading phases .............................................................................................................111
Loading the ISO container............................................................................................ 114
Unloading phases......................................................................................................... 130
Unloading an ISO container ......................................................................................... 132
Releasing the liftframe from the ISO container............................................................. 135
Moving the liftframe onto the XR21S stowage ............................................................. 139
Locking the liftframe to the stowage............................................................................. 142
Removing the liftframe from XR21S gripping hook and leaving it on stand supports .. 145
Tipping an ISO container IS NOT allowed!................................................................... 151
Design description ..................................................................................................... 152
Technical specications................................................................................................ 152
Construction ................................................................................................................ 154
Hydraulics..................................................................................................................... 154
Control devices, 2GCC................................................................................................. 156
EQUIPMENT ................................................................................................................ 157
Locking mechanisms of the hook ................................................................................. 159
Protection of main cylinder ........................................................................................... 163

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MAINTENANCE........................................................................................................... 164
Service Indicator........................................................................................................... 164
Service table................................................................................................................. 168
Hydraulics service ........................................................................................................ 170
Safety functions............................................................................................................ 176
General inspection........................................................................................................ 178
Electric system ............................................................................................................. 180
Emergency operation ................................................................................................... 180
How to change the backlight setting of the buttons...................................................... 182
FAULT FINDING .......................................................................................................... 185
MULTILIFT PLC - Diagnostic Codes ............................................................................ 185
XR S SENSORS........................................................................................................... 204
LUBRICATION ............................................................................................................. 205
DELIVERY CARD ........................................................................................................ 209

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XR21S56 CHU XR21S59 CHU
MULTILIFT XR S CHU HOOKLIFT
User Manual
This manual concerns the MULTILIFT XR21S CHU hooklift equipment.
Information about the equipment.
Type of system:
Serial number:
Date of commissioning:
Owner
Your Multilift dealer
Service workshop:
This manual is a translation from the original operating instructions
compiled in Finnish.

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MULTILIFT XR21S hooklift equipment
Note!
Cargotec Finland Oy reserves the right to change specications, equipment, operating and
maintenance instructions without prior notice.
GENERAL DESCRIPTION
MULTILIFT XR hooklift equipment is an exchange container loading and unloading device
mounted on a truck chassis. An experience of over 60 years is a proof of the reliability and
versatility of the equipment all over the world.
CE Statement of Conformity
Cargotec Finland Oy Multilift has been an ISO 9001 certied company since 1995 and
since 2002 the company has complied with the ISO 14001 environmental standard.
Multilift guarantees that the equipment contained within this manual conforms with the
EC Machine Directive.
Cargotec Finland Oy
Multilift
Raisio
Finland
2017

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6
7
2
4
10
5
3
9
11
12
17
16
18
8
15
13
14
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, hydraulic
4. Rear frame
5. Rear rollers
6. Sub-frame
7. Main cylinders
8. Body locking cylinder (inside the frame beam of the lockings)
9. Mechanical tipping lock
10. Body support
11. Control valve
12. Load holding valve of the main cylinder
13. Telescope cylinder (inside the middle frame)
14. Double check valve of the telescope cylinder
15. Locking cylinder check valve
16. Liftframe
17. Stowage
18. ISO container support rollers

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A1
FLAT
A2
TIP
A3
ISO
A4
STO
A5
MAN
Control unit
Control lever
CAN bus cable
Telescopic arm forward (M)
Hook safety lock
Telescopic arm backward (M)
Signal lights
Bodylocks close
A1 Flatrack (A)
A3 ISO (A)
A5 Manual mode (M)
Telescopic arm forward (M)
Hook safety lock
Telescopic arm backward (M)
Four digit display
(point: voltage OK
and system OK)
Bodylocks open
A2 Tip (A)
A4 Stowage mode
Control lever
Auto mode (A) - Sequenced Load & Unload
Manual mode (M) - Only Main cylinders Load & Unload
forward
backward
The buzzer which is tted in the control unit is active as follows:
- In Auto modes (A1, A2, A3) when the telescopic arm isn`t fully forward.
- In Manual mode (A5) when the telescopic arm isn`t in fully forward.
- In Stowage mode (A4) when the telescopic arm isn`t in fully forward.
Control lever

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Signal lights of control unit
Middle frame Hook of stowage
Body locks URB
SIGNAL LIGHT O󰀨 Blinking On
Middle frame Middle frame
down
Middle frame
almost down
(oating)
Middle frame is
raised
Body locks Body locks are
closed or the pull
limiter is engaged
Body locks are
in transitional
position
Body locks are
open or the pull
limiter is not
engaged
Under-run bar Under-run bar is
fully extended
Under-run bar
is in transitional
position
Under-run bar is
fully retracted
Stowage hook Stowage hook
down (in)
Stowage hook
in transitional
position
Stowage hook up
(out)

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Control system
CONTROL UNIT
All the switches needed to operate the XR21S -equipment can be found on the control unit.
A movement (manual mode) or a series of movements (automatic mode) is selected in
the control unit.
Moving the control lever on the control unit enables movement or series of movements in
di󰀨erent directions.
The four digit display on the control unit gives information about faults, errors and di󰀨erent
phases of operation.
CONTROL SYSTEM LOGIC
The operations are controlled by a logic, which has been programmed into the control
system. An approach switch sends signals to the logic, giving it information about the
operational phases of the equipment.
The device can be either driven in automatic mode (A1 - A3), or in manual mode (A5),
one movement at a time.
If a fault occurs (e.g. approach switch malfunction), the device will stop in automatic mode.
In manual mode it will continue to run, except for the section causing the error. An error
code identies the cause of the interruption.
The error can be reset by turning o󰀨 the power (ignition key) and having another go.

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SYSTEM OPERATION IN AUTOMATIC MODE
In automatic mode the movements are split into the following phases:
1. Loading and unloading a atrack/body
The movements take place in mode A1. Push the A1 button on the control unit for
2 seconds. When the mode is engaged, A1 will blink on the control unit display. The
mode will disengage by pushing the A1 button again, or automatically after 10 minute
if no operations have been used during this time.
A1 mode cannot be selected when the telescopic arm is further forward than the
“FLATRACK HOME POSITION”. Code ”d040” is displayed on the control unit
display when attempting to select the mode.
For unloading the control lever is pulled back, which results in successive movements
of the equipment. The rear rollers must be in “FLATRACK POSITION”.
First the body locks open. After this the horizontal movement and the hook moves
backwards. Tipping lock opens as the horizontal movement comes toward the back.
The main cylinders start after the horizontal movement, and they continue until the
entire atrack/body is on the ground and the control lever is released.
Loading is split into similar stages. It takes place as successive movements, by
holding the control lever pushed forward.
The movements are as above, but in opposite order.
The main cylinders are released (oating) when the atrack/body is about 60 mm
above the body supports, and the nal phase of loading is dampened.
Horizontal movement is the nal operation and it can be stopped by releasing the
control lever, when the atrack/body is in the correct place (short ones).
Movement of the telescope cylinder during atrack/body change is restricted to
approx. 350 mm before the extreme front position (“FLATRACK HOME POSITION”).
The locks will engage automatically.
The biggest horizontal movement is 1100 mm (in manual mode).

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2. Tipping and lowering the tipping device
The movements take place in mode A2 (push the A2 button on the control unit for 2
seconds). When the mode is engaged, A2 will blink on the control unit display.
The mode will disengage by pushing the A2 button again, or automatically after 10 min
if no operations have been used during this time.
Mode cannot be selected when the telescopic arm is more to the front, than “FLATRACK
HOME POSITION or CONTAINER HOME POSITION”. Code ”d040” is displayed on
the control unit display when attempting to select the mode.
The operations are the same as those in manual mode, except:
When tipping is started by pulling the control lever backwards, the logic ensures that
the locks are engaged by activating the BODYLOCKS CLOSE function for approx.
0,5 s. After this the main cylinders lift the atrack/body if the body locks are closed, the
pull limiter in engaged and the under-run bar is retracted.
Afterwards, as the atrack/body is being lowered, movement speed is automatically
reduced before the atrack/body is lowered onto the body supports.
3. Loading and unloading an ISO container (Liftframe must be used)
The movements take place in mode A3. Push the A3 button on the control unit for
2 seconds. When the mode is engaged, A3 will blink on the control unit display. The
mode will disengage by pushing the A3 button again, or automatically after 10 min if
no operations have been used during this time.
Mode cannot be selected when it is more to the front, than the front position of atrack/
body change (approx. 350 mm behind the far-front position). Code ”d040” is displayed
on the control unit display when attempting to select the mode. The liftframe ratchets
must also be attached to the stowage, ”d019” is visible on the control unit display.
For unloading the control lever is pulled back, which results in successive movements
of the equipment. Rear rollers must be in ”CONTAINER MODE”.

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The TWIST LOCK-locks need unlocking. First the body locks open.
After this the horizontal movement and hook movement backwards take place.
Tipping lock opens as the horizontal movement comes towards the back.
The main cylinders start after the horizontal movement, and continue until the entire
ISO container is resting on the ground and the control lever is released.
Loading is split into similar stages. It takes place as successive movements, by
holding the control lever pushed forward.
The movements are as above, but in opposite order. The main cylinders are
released (oating) when the atrack/body is about 60 mm above the body supports,
and the nal stage of loading is dampened.
Horizontal movement is the nal operation and it can be stopped by releasing the
control lever when the atrack/body is in the right place (short containers).
Movement of the telescope cylinder during ISO container change is restricted so,
that the corner locks at the back end of the ISO container meet the TWIST-LOCKS
at the back end of the ISO container support rollers (“CONTAINER HOME
POSITION”). The twist locks do not engage automatically.
The purpose of these phases is:
1. Horizontal movement at the beginning of loading and unloading is done by a sliding
horizontal movement. Because of this the front of the atrack/body is not lifted
during horizontal movement, as is normally the case during tilting.
As a result the horizontal movement can be stopped at any time, depending on the
atrack/body length.

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SYSTEM OPERATION IN MANUAL MODE
Manual mode must be used in special situations, such as handling longer or shorter atrack/
bodies than usual, handling containers in shallow spaces or on uneven ground and loading
or unloading them on/from a platform or a trailer.
The movements take place in mode A5 (push the A5 button on the control unit for 2 seconds).
When the mode is engaged, A5 will blink on the control unit display.
The mode will disengage by pushing the A5 button again, or automatically after 10 min if
no operations have been used during this time.
The horizontal movement is prevented when it is more to the front than the front position
of atrack/body change (approx. 350 mm behind the far-front position = “STOW/UNSTOW
POSITION”). The liftframe ratchets must also be attached to the stowage. Otherwise ”d019”
will be visible on the control unit display.
In manual mode the main cylinders are controlled by moving the control lever to the front and
the back. If the body locks are open, the XR21S -equipment is in loading/unloading mode.
If they are closed, the XR21S -equipment is in tipping mode. See terms of use in mode A2.
The telescope cylinder is controlled by rocker switches on the sides of control unit, by
pushing its front or back. The body locks must be open. The horizontal cylinder stroke has
not been restricted.
The movements in manual mode should be phased as in automatic mode.
As explained earlier, the horizontal movement is long, and during atrack/body change it
has been restricted to approx. 350 mm before the far-front position.

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CHANGING OPERATION IN DIFFERENT SITUATIONS
Each operation can be stopped at any time by releasing the switch, and continued or
changed depending on the operation phase (but not changed e.g. from tipping to changing
the atrack/body) by going to the desired operation and pressing its switch.
Changing the control method (automatic mode/manual mode)
1. Changing from automatic mode to manual mode
The control method can always be changed to manual, under all circumstances.
2. Changing from manual mode to automatic mode.
2.1 Automatic mode can be engaged, if the tilting movement is fully in the front
position, the locks will close
- tipping and unloading are possible.
2.2 Automatic mode cannot be engaged if the tilting movement is in a position
other than front position, a warning buzzer can be heard in the cabin.
AUTOMATIC MODE should be used whenever possible.
Automatic mode can be used during loading and unloading of containers with widely
used lengths.
The atrack/body length in automatic mode should be:
at least 4,6 m (G-size - 0,7 m) G-size = geometric length of the equipment 5,3 m,
max. 6,3 m (G-size + 1,0 m) measurement from the middle line of the hook to the
middle of the rear rollers
Shorter or longer containers must be handled in manual mode.
Even containers with these dimensions should be handled in manual mode
when loading on uneven ground.

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Normally automatic mode can always be used during tipping.
Horizontal movement of the XR21S equipment is restricted for safety reasons, i.e. standard
containers won't collide with the equipment on level ground.
As stated before, the user friendly automatic mode should always be used, whenever the
atrack/body length allows it.
Manual mode should always be used in special cases (loading in shallow spaces,
loading a atrack/body on a trailer or a platform).

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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.
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 atrack/body 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.
XR hooklift equipment may only be used when sitting on the driver´s seat.
If it is necessary to leave the cabin during loading, unloading or tipping,
always engage the parking brake and disengage the power take-o󰀨.

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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.
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 (< 0°C) 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 atrack/body 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 atrack/body.
The locking signal light is red and it is lit when the body and tipping locks are OPEN (changing
a atrack/body). The light blinks when the body and/or tipping locks are in a transitional
position, i.e. their movement is prevented.
If the light doesn’t go out when the locks are engaged, or if it isn’t lit when they are open,
investigate and x the cause immediately.
If the vehicle is left in a public place, the demountable should always be left in transport
position on top of the sub frame.
Check that the atrack/body is suitable for the load to be transported.
Ice can build up in the equipment in subzero temperatures 0oC. This may hinder or prevent
some movements.

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Note!
Any faulty operation or movement must be stopped immediately by shutting
o󰀨 the oil supply of the hydraulic pump.
Never keep hydraulics engaged if the auxiliary device needing it is
not in use.
The switch unit outside the cabin is equipped with an emergency stop switch.
Let the engine run at idle speed at the beginning and end of movements, otherwise follow
the recommended pump speed.
The pressure settings of the equipment should not be changed.

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! !
Requirements for the working area ground condition
Before you start loading, unloading or tipping, 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