MULTILIFT XR S User And Maintenance Manual Download Page 195 | Manualshive

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XR21S59 CHU

195

1/2018

113813003

Hooklift Multilift XR21S59 CHU

Service Manual

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ERROR CODE

COMMENTS / PROBLEM

LOCATION

PROGRAM DESCRIPTION

POSSIBLE ACTION

CONSEQUENCE

CONFLICTS

C000

NONE OR SEVERAL INPUTS PRESENT AT MODE SWITCH

CONTROL BOX

MODE SWITCH CONFLICT

REPLACE BOX

NO HOOKLIFT

FUNCTION

C001

VALUES FROM JOYSTICK NOT LEGAL

CONTROL BOX

JOYSTICK CONFLICT

REPLACE JOYSTICK

NO HOOKLIFT

FUNCTION

C002

BOTH INPUTS PRESENT AT CONTROL BOX

CONTROL BOX

ROCKER SWITCH

CONFLICT 1

REPLACE ROCKER SWITCH 1

C003

BOTH INPUTS PRESENT AT CONTROL BOX

CONTROL BOX

ROCKER SWITCH

CONFLICT 2

REPLACE ROCKER SWITCH 2

C004

BOTH INPUTS PRESENT AT CONTROL BOX

CONTROL BOX

ROCKER SWITCH

CONFLICT 3

REPLACE ROCKER SWITCH 3

C005

BOTH INPUTS PRESENT AT CONTROL BOX

CONTROL BOX

ROCKER SWITCH

CONFLICT 4

REPLACE ROCKER SWITCH 4

C006

BOTH INPUTS PRESENT AT CONTROL BOX

CONTROL BOX

ROCKER SWITCH

CONFLICT 5

REPLACE ROCKER SWITCH 5

C007

MIDDLE FRAME DOWN SENSOR IS 1 AND REAR FRAME IS 0

HOOKLIFT

INPUTS CONFLICT 1

CHECK MIDDLE FRAME DOWN & REAR FRAME DOWN

SENSORS - REPLACE IF NECESSARY

C008

MIDDLE FRAME DOWN SENSOR IS 1 AND MIDDLE FRAME

NEARLY DOWN IS 0

HOOKLIFT

INPUTS CONFLICT 2

CHECK MIDDLE FRAME DOWN & MIDDLE FRAME NEARLY

DOWN SENSORS - REPLACE IF NESSECARY

C009

BODYLOCKS OPEN IS 1 AND BODYLOCKS CLOSED IS 1

HOOKLIFT

INPUTS CONFLICT 3

CHECK BODYLOCKS OPEN AND BODYLOCKS CLOSED

SENSORS - REPLACE IF NECESSARY

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Summary of Contents for XR S

Page 1: ...MULTILIFT XR S 1 2018 Hooklift XR21S59 CHU USER AND MAINTENANCE MANUAL 113813003 EN ...

Page 2: ...round condition 20 Working area 21 Flatrack body 23 Loading and unloading of a flatrack body 25 Tipping 29 Before driving away 30 Safety facilities of the XR S hooklift equipment 31 HOOKLIFT OPERATION 33 Loading a flatrack body 35 Loading a short flatrack body 49 Tipping a flatrack body 55 Lowering the tipping device 61 Unloading a flatrack body 65 Loading of rear heavy flatrack body 79 Unloading ...

Page 3: ... 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 Techni...

Page 4: ...ndicator 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 ...

Page 5: ...R 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 ...

Page 6: ...ainer 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 certified company since 1995 and since 2002 the company has complied with the ISO 14001 environmental standard Multilift guarantees that the equipm...

Page 7: ...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 v...

Page 8: ... 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 fitted 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 th...

Page 9: ...ame almost down floating 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 ...

Page 10: ...rrors and different 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 swi...

Page 11: ...K 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 flatrack body is on the ground and the control lever is released Loading is split into similar stages It takes place as successive movements ...

Page 12: ... flatrack body if the body locks are closed the pull limiter in engaged and the under run bar is retracted Afterwards as the flatrack body is being lowered movement speed is automatically reduced before the flatrack 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 ...

Page 13: ...ut 60 mm above the body supports and the final stage of loading is dampened Horizontal movement is the final operation and it can be stopped by releasing the control lever when the flatrack 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...

Page 14: ...nt position of flatrack 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 I...

Page 15: ...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 wide...

Page 16: ...21S 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 flatrack body length allows it Manual mode should always be used in special cases loading in shallow spaces loading a flatrack body on a trailer or a platform ...

Page 17: ...ctly adhere to the safety instructions specified in this manual or due to carelessness during the operation adjustment maintenance or repair of the hooklift equipment Depending on the specific 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 instruct...

Page 18: ...he 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 effect on the operation during loading unloading or tipping of the flatrack body The locking ...

Page 19: ...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 ...

Page 20: ...quirements for the working area ground condition Before you start loading unloading or tipping you must inspect the following the ground must be firm and free from potholes into which the truck could move during operation the ground must not be slippery the ground must be level ...

Page 21: ...pace this also applies to free height There must be at least 10 m free space at both sides of the vehicle Check the vicinity for possible dangers When loading the flatrack body 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 ...

Page 22: ...river 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 flatrack body Tip Mark out the working area for example with cones In case of emergency Shut off the oil supply of the hydraulic pump ...

Page 23: ...up the flatrack body 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 flatrack body dimensions measure them first in order to prevent the XR equipment and the flatrack body from being damaged Gripping height H tunnel height T and width ...

Page 24: ...on 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 flatrack body are under heady burden Carry out daily checks of these components for wear or damage If the flatrack body is frozen to ...

Page 25: ...ding is normally done by using the middle frame and the sliding frame Ensure before loading that the length of the flatrack body is suitable for your XR hooklift equipment Loading of a rear heavy flatrack body requires special care Never load unload or tip a flatrack body when the load is heavier to one side or the ground is sloping ...

Page 26: ...ion the flatrack body in line by lifting the front end of it approx 10 cm and pulling it forward by truck This will prevent the flatrack body from being pulled outside the rear rollers and the hooklift and rear lights being damaged When moving the flatrack body to get it in line with the truck first remove all obstacles in front of the flatrack body When loading or unloading a flatrack body ensure...

Page 27: ...topped in time the truck rear end will be lifted up from the ground which will cause damaging of the flatrack body truck or the hooklift equipment Before picking up the flatrack body the gripping bar of the flatrack body must be properly inside the lifting hook In this way you prevent the flatrack body from falling The situation must be checked by lifting the flatrack body approx 10 cm and after t...

Page 28: ...on and check for any possible unusual or disruptive movements or sounds caused by the flatrack body If you notice anything like this STOP THE OPERATION 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 flatrack body or the XR equipment The disruption must be remedied before the operation is contin...

Page 29: ...ks NEVER TIP UNDER THE FOLLOWING CIRCUMSTANCES Flatrack body is top heavy at the front end or at either side Load is frozen or only partially loose Ground is slippery or uneven Strong side wind which exceeds over 20 m s If it is necessary to drive with the tipping device up pay attention to the vicinity regarding the height of the hooklift equipment flatrack body with respect to the surroundings l...

Page 30: ...cured and covered All red flatrack body signal lights on the control unit instrument panel must be out If a signal light on the control unit does not go out when the body locking system is locked there is a malfunction which must be corrected immediately When there is no flatrack body mounted the XR S hooklift equipment must be positioned in its transport position on the sub frame both during driv...

Page 31: ...ave safety features Hydraulic body locks cannot be opened during tipping Hydraulic body locks cannot be closed during loading and unloading If the body locks are closed it is not possible to move the hook arm Moving the hook arm is not possible during tipping When tipping the rear frame and the middle frame are locked together by the tipping lock The lock operates mechanically Tipping action canno...

Page 32: ...data gathered or created by such System including but not limited to information concerning operation operating environment movement condition logon location and similar information relating to the Equipment the Information The Customer shall not in any way remove or alter the System nor interfere with the use of the System or the Information The System and the Information and all their further de...

Page 33: ...in the ISO container position picture 2 2 Pull the longer roller locking pin out to the point where the roller can be moved do not pull the whole locking pin out 3 Turn the roller to an upright position Lock the roller to this position by pushing the locking pin back in 4 Pull the shorter roller locking pin off lower the front part of the roller and lock it to down position with the locking pin ho...

Page 34: ...t Multilift XR21S59 CHU User Manual 5 m 1 2 3 4 350 2 3 A1 FLAT A2 TIP A3 ISO A4 STO A5 MAN A1 FLAT A2 TIP A3 ISO A4 STO A5 MAN 5 A M Liftframe not shown in stowage for clarity The numbers refer to the operation instructions on the next page ...

Page 35: ... engine run at idle speed at the beginning and end of movements and when using the locks NOTE Unnecessary use of the main pressure relief valve should be avoided because this may overheat the oil 1 See the safety instructions before loading 2 Reverse the truck carefully close to the flatrack body Stop it about 5 meters from the flatrack body gripping bar 3 Engage the parking brake 4 Engage the hyd...

Page 36: ...ilift XR21S59 CHU User Manual 6A A1 FLAT A2 TIP A3 ISO A4 STO A5 MAN A6 URB 6B 350 A1 FLAT A2 TIP A3 ISO A4 STO A5 MAN A5 M 7 A1 FLAT A2 TIP A3 ISO A4 STO A5 MAN A6 URB A1 FLAT A2 TIP A3 ISO A4 STO A5 MAN A6 URB A M CHECK THE RATCHET LOCATION OPEN ...

Page 37: ...in front of the flatrack body home position push the A5 button for approx 2 s push the rearmost button in the bottom row on the either side of the control unit horizontal movement slides backwards cylinder in stop the horizontal movement after it has moved at least 350 mm backwards 7 Open the body locks push the bodylocks open button locks not closed signal light on the control unit is lit when th...

Page 38: ...13813003 Hooklift Multilift XR21S59 CHU User Manual 8 A1 FLAT A2 TIP A3 ISO A4 STO A5 MAN A1 FLAT A2 TIP A3 ISO A4 STO A5 MAN A M 9 A1 FLAT A2 TIP A3 ISO A4 STO A5 MAN A6 URB A1 FLAT A2 TIP A3 ISO A4 STO A5 MAN A6 URB A M 10 ...

Page 39: ...middle frame back drive the middle frame back by moving the control lever back main cylinders out frame not down signal light is lit when the middle frame is lifted off the sub frame stop the movement by releasing the control lever when the hook is slightly below the flatrack body gripping bar 9 Middle frame back keep the control lever in rear position Middle frame turns back main cylinders out fr...

Page 40: ...XR21S59 CHU 40 1 2018 113813003 Hooklift Multilift XR21S59 CHU User Manual A1 FLAT A2 TIP A3 ISO A4 STO A5 MAN A6 URB A1 FLAT A2 TIP A3 ISO A4 STO 11 A M LIFT CHECK REVERSE THE LOCKING ...

Page 41: ...trol lever when the hook starts to lift the flatrack body Make sure that the gripping bar is properly inside the lifting hook and the safety lock is engaged Choose automatic mode A1 push the A1 button for approx 2 s 11 The flatrack body comes free from the ground move the control lever slowly forward signal lights locks not closed URB in and frame not down on the control unit are lit main cylinder...

Page 42: ...XR21S59 CHU 42 1 2018 113813003 Hooklift Multilift XR21S59 CHU User Manual 12A Min 2 m A1 FLAT A2 TIP A3 ISO A4 STO A5 MAN M 12 A1 FLAT A2 TIP A3 ISO A4 STO A5 MAN A1 FLAT A2 TIP A3 ISO A4 STO A M ...

Page 43: ...latrack body in the picture should not come in contact with the rear rollers of the rear beam The situation can be prevented by lifting the flatrack body with horizontal movement Note Horizontal movement during loading can only be done in manual mode A5 12A Horizontal movement during loading only in manual mode A5 Select manual mode A5 push the A5 button for approx 2 s Drive the telescope cylinder...

Page 44: ...8 113813003 Hooklift Multilift XR21S59 CHU User Manual 15 A1 FLAT A2 TIP A3 ISO A4 STO A5 MAN A6 URB A1 FLAT A2 TIP A3 ISO A4 STO A5 MAN A6 URB A M 13 14 A M A1 FLAT A2 TIP A3 ISO A4 STO A5 MAN A1 FLAT A2 TIP A3 ISO A4 STO ...

Page 45: ...k body is lifted in line with the rear rollers Steering the truck will ensure simultaneous contact between the flatrack body and both rear rollers 14 Activate the handbrake when the rear end of the flatrack body is lifted from the ground Safety codes 15 Middle frame forward end of the movement keep the control lever in front main cylinder piston rods move inwards frame not down signal light on the...

Page 46: ... 1 2018 113813003 Hooklift Multilift XR21S59 CHU User Manual 16 A1 FLAT A2 TIP A3 ISO A4 STO A5 MAN A5 MAN A M A1 FLAT A2 TIP A3 ISO A4 STO A5 MAN A6 URB A1 FLAT A2 TIP A3 ISO A4 STO A5 MAN A6 URB A5 MAN 17 A M CLOSE ...

Page 47: ... the rear rollers The main cylinders are released floating when the flatrack body is about 60 mm above the body supports and the final stage of unloading is dampened 16 Horizontal movement forward keep the control lever in the front telescope cylinder out Release the switch when the flatrack body is in the right place short ones or the system has stopped the horizontal movement Make sure the rear ...

Page 48: ...XR21S59 CHU 48 1 2018 113813003 Hooklift Multilift XR21S59 CHU User Manual SHORT FLATRACK BODY ...

Page 49: ...y length XR21S56 4 6 m and XR21S59 4 9 m A short flatrack body is loaded in the same way as a regular size flatrack body except that the movement of the horizontal movement is left out Close the locks after the flatrack body has been lowered on to the body supports NOTE DO NOT DRIVE THE FLATRACK BODY OVER AND IN FRONT OF THE REAR ROLLERS ...

Page 50: ...120 AND THE CABLE LOCKS CAN BE OPENED C009 BODY LOCKS OPEN SENSOR 316 AND BODY LOCKS CLOSED SENSOR 317 ARE BOTH ACTIVE CHECK WHY SENSOR 317 IS ACTIVE LOCKS CAN BE OPENED SAFETY CODE DESCRIPTION NOTE C007 d012 REAR FRAME DOWN SENSOR 318 IS NOT ACTIVE CHECK THE SENSOR AND CABLE HOOK ARM IS NOT MOVING C009 d001 BODY LOCKS OPEN SENSOR 316 AND BODY LOCKS CLOSED SENSOR 317 ARE BOTH ACTIVE CHECK WHY SENS...

Page 51: ...21 URB OUT SENSOR 323 IS ACTIVE CHECK THE SENSOR AND CABLE MAIN CYLINDERS NOT MOVING OUT d022 URB IN SENSOR 322 AND URB OUT SENSOR 323 ARE NOT ACTIVE CHECK SENSOR 322 AND CABLE MAIN CYLINDERS NOT MOVING OUT SAFETY CODE DESCRIPTION NOTE C009 d003 d015 BODY LOCKS CLOSED SENSOR 317 IS ACTIVE CHECK THE SENSOR AND CABLE MAIN CYLINDERS ARE MOVING OUT d003 d015 BODY LOCKS OPEN SENSOR 316 IS NOT ACTIVE CH...

Page 52: ...OWN SENSOR 318 IS NOT ACTIVE CHECK THE SENSOR AND CABLE MAIN CYLINDERS ARE MOVING IN SAFETY CODE DESCRIPTION NOTE C007 d012 REAR FRAME DOWN SENSOR 318 IS NOT ACTIVE CHECK THE SENSOR AND CABLE HOOK ARM IS NOT MOVING FRONT C008 MIDDLE FRAME NEARLY DOWN SENSOR 120 IS NOT ACTIVE CHECK THE SENSOR AND CABLE HOOK ARM IS MOVING FRONT C009 d001 BODY LOCKS OPEN SENSOR 316 AND BODY LOCKS CLOSED SENSOR 317 AR...

Page 53: ...CODE DESCRIPTION NOTE C007 d012 REAR FRAME DOWN SENSOR 318 IS NOT ACTIVE CHECK THE SENSOR AND CABLE LOCKS CAN BE CLOSED C008 MIDDLE FRAME NEARLY DOWN SENSOR 120 IS NOT ACTIVE CHECK THE SENSOR AND CABLE LOCKS CAN BE CLOSED C009 BODY LOCKS OPEN SENSOR 316 AND BODY LOCKS CLOSED SENSOR 317 ARE BOTH ACTIVE CHECK THE SENSORS AND CABLE LOCKS CAN BE CLOSED ...

Page 54: ...XR21S59 CHU 54 1 2018 113813003 Hooklift Multilift XR21S59 CHU User Manual A1 FLAT A2 TIP A3 ISO A4 STO A5 MAN A1 FLAT A2 TIP A3 ISO A4 STO A5 MAN 5 A M 6 ...

Page 55: ...R 2 Drive the truck to the place where the load has to be discharged 3 Engage the parking brake 4 Engage the hydraulic pump Safety codes 5 Select automatic mode A2 push the A2 button approx 2 s 5 Choose manual mode A5 push the A5 button for approx 2 s MANUAL MODE A5 AUTOMATIC MODE A2 6 Open the flatrack body tail gate note the flatrack body operating instructions stand by the side of the flatrack ...

Page 56: ...t Multilift XR21S59 CHU User Manual A1 FLAT A2 TIP A3 ISO A4 STO A5 MAN A6 URB A1 FLAT A2 TIP A3 ISO A4 STO A5 MAN A6 URB A5 MAN 7 A M 8 A1 FLAT A2 TIP A3 ISO A4 STO A5 MAN A6 URB A1 FLAT A2 TIP A3 ISO A4 STO A5 MAN A6 URB A5 MAN A M SECURE ...

Page 57: ...he under run bar is fully in the in position the system will close the body locks if they are open locks not closed signal light should not be lit the middle rear frame tipping lock must be closed 8 Raise the tipping device middle frame together with the rear frame into the desired or the maximum tipping angle move the control lever slowly backwards make sure the flatrack body doesn t hit the rear...

Page 58: ...XR21S59 CHU 58 1 2018 113813003 Hooklift Multilift XR21S59 CHU User Manual 9 10 11 ...

Page 59: ...e forward in order to empty the complete contents of the flatrack body the PTO can be engaged during this phase 11 Engage the parking brake Safety codes 9 Decrease the speed of tipping movement to prevent an abrupt stop during the last tipping phase 9 Decrease the speed of tipping movement to prevent an abrupt stop during the last tipping phase ...

Page 60: ...XR21S59 CHU 60 1 2018 113813003 Hooklift Multilift XR21S59 CHU User Manual 12 13 14 15 16 A1 FLAT A2 TIP A3 ISO A4 STO A5 MAN A6 URB A1 FLAT A2 TIP A3 ISO A4 STO A5 MAN A6 URB A5 MAN A M ...

Page 61: ...frame move the control lever forward stop the movement by releasing the control lever The main cylinders are released floating when the flatrack body is about 60 mm above the body supports and the final stage of unloading is dampened 13 Check that the frame of the XR21S equipment and the flatrack body are in the lowest position 14 Close the flatrack body tail gate 15 Shut off the oil supply of the...

Page 62: ...S ACTIVE CHECK THE SENSOR 120 AND THE CABLE TIPPING IS WORKABLE C009 d000 d004 BODY LOCKS OPEN SENSOR 316 AND BODY LOCKS CLOSED SENSOR 317 ARE BOTH ACTIVE CHECK WHY SENSOR 316 IS ACTIVE TIPPING IS WORKABLE d003 TIPPING LOCK CLOSED SENSOR 319 HAS LOST SIGNAL CHECK THAT TIPPING LOCK IS CLOSED AND SENSOR ACTIVE TIPPING IS PREVENTED d004 BODY LOCKS CLOSED SENSOR 317 IS NOT ACTIVE TIPPING IS PREVENTED ...

Page 63: ...SED SENSOR 319 HAS LOST SIGNAL CHECK THE SENSOR 119 AND THE CABLE TIPPING IS PREVENTED d015 HOOK ARM BACK SENSOR 320 IS ACTIVE CHECK THE SENSOR AND CABLE TIPPING IS PREVENTED d021 URB OUT SENSOR 323 IS ACTIVE CHECK THE SENSOR TIPPING IS PREVENTED d022 URB IN SENSOR 322 IS ACTIVE CHECK THE SENSOR TIPPING IS PREVENTED SAFETY CODE DESCRIPTION NOTE C009 d012 BODY LOCKS OPEN SENSOR 316 AND BODY LOCKS C...

Page 64: ... 2018 113813003 Hooklift Multilift XR21S59 CHU User Manual 1 2 3 4 5 7 A1 FLAT A2 TIP A3 ISO A4 STO A5 MAN A6 URB A1 FLAT A2 TIP A3 ISO A4 STO A5 MAN A1 FLAT A2 TIP A3 ISO A4 STO A5 MAN 6 A M CHECK THE RATCHET LOCATION ...

Page 65: ...3 Check the working area ensure that there is enough space in front rear and above the truck 4 Engage the parking brake 5 Engage the hydraulic pump 6 Choose manual mode A5 push the A5 button for approx 2 s 6 Choose automatic mode A1 push the A1 button for approx 2 s MANUAL MODE A5 AUTOMATIC MODE A1 Safety codes 7 If it seems impossible to select the mode and code d019 is displayed on the control u...

Page 66: ...2018 113813003 Hooklift Multilift XR21S59 CHU User Manual 9 A1 FLAT A2 TIP A3 ISO A4 STO A5 MAN A1 FLAT A2 TIP A3 ISO A4 STO A5 MAN A M 8 A1 FLAT A2 TIP A3 ISO A4 STO A5 MAN A1 FLAT A2 TIP A3 ISO A4 STO A5 MAN A M OPEN ...

Page 67: ...t is not in URB signal light on the control unit is lit when the under run bar is fully in the in position body locks will open when the locks are open the locks not closed signal light on the control unit is lit 9 Drive the horizontal movement into rear position push the rearmost button in the bottom row on the either side of the control unit horizontal movement slides backwards cylinder in mecha...

Page 68: ...TIP A3 ISO A4 STO A5 MAN A6 URB A M 12 1 3 B 2 A 2 4 1 3 B 2 A 2 4 A1 FLAT A2 TIP A3 ISO A4 STO A5 MAN A6 URB A1 FLAT A2 TIP A3 ISO A4 STO A5 MAN A6 URB A M NOTE In some cases the flatrack body will push the truck forward Assist this if necessary by steering the truck and simultaneously holding the control lever in backward position Safety codes ...

Page 69: ... front end of the flatrack body to the ground 3 continue the downward motion of the main cylinders with the safety lock open until the hook is released from the gripping bar 4 stop the movement by releasing the control lever 12 Middle frame backwards open the safety lock of the gripping hook and release the hook from the flatrack body gripping bar 1 keep the control lever in rear position main cyl...

Page 70: ...XR21S59 CHU 70 1 2018 113813003 Hooklift Multilift XR21S59 CHU User Manual 13 14 A1 FLAT A2 TIP A3 ISO A4 STO A5 MAN A6 URB A1 FLAT A2 TIP A3 ISO A4 STO A5 MAN A6 URB A M ...

Page 71: ...g when the flatrack body is about 60 mm above the body supports and the final stage of unloading is dampened Stop the movement when the middle frame rests on the sub frame by releasing the control lever Continue in automatic mode A1 14 Middle frame forward beginning of the movement move the control lever forward signal lights locks not closed URB in and frame not down on the control unit are lit t...

Page 72: ...klift Multilift XR21S59 CHU User Manual A1 FLAT A2 TIP A3 ISO A4 STO A5 MAN A6 URB A1 FLAT A2 TIP A3 ISO A4 STO A5 MAN A6 URB A5 MAN 16 17 18 A M 15 A1 FLAT A2 TIP A3 ISO A4 STO A5 MAN A1 FLAT A2 TIP A3 ISO A4 STO A5 MAN A5 MAN A M CLOSE ...

Page 73: ...eached the flatrack body home position approx 350 mm from the stow unstow position of horizontal movement 16 Closing body locks close the body locks by pressing the bodylocks close button the signal light locks not closed should go out 16 Closing body locks body locks close when the control lever is released the locks not closed signal light on the control unit goes out Always drive in traffic wit...

Page 74: ...N BE OPENED C009 BODY LOCKS OPEN SENSOR 316 AND BODY LOCKS CLOSED SENSOR 317 ARE BOTH ACTIVE CHECK WHY SENSOR 317 IS ACTIVE LOCKS CAN BE OPENED SAFETY CODE DESCRIPTION NOTE C007 d012 REAR FRAME DOWN SENSOR 318 IS NOT ACTIVE CHECK THE SENSOR AND CABLE HOOK ARM IS NOT MOVING C009 d001 BODY LOCKS OPEN SENSOR 316 AND BODY LOCKS CLOSED SENSOR 317 ARE BOTH ACTIVE CHECK WHY SENSOR 317 IS ACTIVE HOOK ARM ...

Page 75: ...21 URB OUT SENSOR 323 IS ACTIVE CHECK THE SENSOR AND CABLE MAIN CYLINDERS NOT MOVING OUT d022 URB IN SENSOR 322 AND URB OUT SENSOR 323 ARE NOT ACTIVE CHECK SENSOR 322 AND CABLE MAIN CYLINDERS NOT MOVING OUT SAFETY CODE DESCRIPTION NOTE C009 d003 d015 BODY LOCKS CLOSED SENSOR 317 IS ACTIVE CHECK THE SENSOR AND CABLE MAIN CYLINDERS ARE MOVING OUT d003 d015 BODY LOCKS OPEN SENSOR 316 IS NOT ACTIVE CH...

Page 76: ...AME DOWN SENSOR 318 IS NOT ACTIVE CHECK THE SENSOR AND CABLE MAIN CYLINDERS ARE MOVING IN SAFETY CODE DESCRIPTION NOTE C007 d012 REAR FRAME DOWN SENSOR 318 IS NOT ACTIVE CHECK THE SENSOR AND CABLE HOOK ARM IS NOT MOVING FRONT C008 MIDDLE FRAME NEARLY DOWN SENSOR 120 IS NOT ACTIVE CHECK THE SENSOR AND CABLE HOOK ARM IS MOVING FRONT C009 d001 BODY LOCKS OPEN SENSOR 316 AND BODY LOCKS CLOSED SENSOR 3...

Page 77: ...CODE DESCRIPTION NOTE C007 d012 REAR FRAME DOWN SENSOR 318 IS NOT ACTIVE CHECK THE SENSOR AND CABLE LOCKS CAN BE CLOSED C008 MIDDLE FRAME NEARLY DOWN SENSOR 120 IS NOT ACTIVE CHECK THE SENSOR AND CABLE LOCKS CAN BE CLOSED C009 BODY LOCKS OPEN SENSOR 316 AND BODY LOCKS CLOSED SENSOR 317 ARE BOTH ACTIVE CHECK THE SENSORS AND CABLE LOCKS CAN BE CLOSED ...

Page 78: ...XR21S59 CHU 78 1 2018 113813003 Hooklift Multilift XR21S59 CHU User Manual 10000 10000 10000 ...

Page 79: ... a risk that the rear frame jumps up If this happens the system stops and d012 can be seen in the display Move the sliding arm slowly more forwards or backwards to get the rear frame down Unloading of a rear heavy flatrack body When unloading a long or rear heavy flatrack body to the ground move the hook arm forward before the flatrack body touches the ground Otherwise there is a danger of the fla...

Page 80: ...8 113813003 Hooklift Multilift XR21S59 CHU User Manual 1 2 3 4 5 6 7 Loading a flatrack body onto a trailer or platform Sliding a flatrack body onto a trailer or a platform must be done in MANUAL MODE A5 OPEN NOTE 1 NOTE 2 ...

Page 81: ...changeable body is not below the level of the trailer or the platform MANUAL MODE 5 Choose manual mode A5 push the A5 button for approx 2 s 6 Open the hydraulic body locks press the bodylocks open button under run bar is retracted if it is not in URB signal light on the control unit is lit when the under run bar is fully in the in position locks not closed signal light is lit on the control unit w...

Page 82: ...ooklift Multilift XR21S59 CHU User Manual 8 9 10 11 NOTE If there is a safety code CXXX and or dXXX in the display then see the chapters Safety codes after the chapters Loading a container Tipping a container and Unloading a container ...

Page 83: ...k body gripping bar open the safety lock of the gripping hook by pressing the button on the control unit just before the front of the flatrack body is lowered to the ground continue the main cylinder movement with the safety lock open and downward until the hook is released from the gripping bar stop the movement by releasing the control lever 11 Move the sliding frame middle frame to forward posi...

Page 84: ...XR21S59 CHU 84 1 2018 113813003 Hooklift Multilift XR21S59 CHU User Manual ...

Page 85: ...e ISO container types The XR21S CHU equipment can be used to transport ISO 668 certified ISO containers with the following dimensions LIFTFRAME USAGE Type IC Length L 20 ft 6058 mm Width W 8 ft 2438 mm Height H 8 ft 2438 mm Type ICC Length L 20 ft 6058 mm Width W 8 ft 2438 mm Height H 8 ft 6 in 2591 mm ...

Page 86: ...Button STOW Button UNSTOW The XR21S emergency stop switch stops the handling functions of a demountable and an ISO container 1 2 3 4 5 UNSTOW pushed down STOW pushed down 1 2 3 4 5 UNSTOW STOW phases Signal light POWER ON The light is lit when the stowage mode A4 or the manual mode A5 is selected ...

Page 87: ... movement moves to the stow unstow position 3 the stowage actuator turns the stowage hook up and lifts the liftframe from the stowage to the XR21S gripping hook 4 the safety lock of the XR21S gripping hook locks the liftframe to the gripping hook of the equipment 5 the stowage actuator turns the stowage hook down Press the STOW button without releasing it 1 body locks open if they are still closed...

Page 88: ...8 113813003 Hooklift Multilift XR21S59 CHU User Manual 5 m 1 2 3 350 2 A1 FLAT A2 TIP A3 ISO A4 STO A5 MAN A1 FLAT A2 TIP A3 ISO A4 STO A5 MAN 4 A M 5A A1 FLAT A2 TIP A3 ISO A4 STO A5 MAN A6 URB CHECK THE RATCHET LOCATION ...

Page 89: ... 1400 k min Let the engine run at idle speed at the beginning and end of movements and when using the locks 1 Reverse the truck carefully close to the liftframe Stop it about 5 meters from the liftframe gripping bar 2 Engage the parking brake 3 Engage the hydraulic pump 4 Choose manual mode A5 push the A5 button for approx 2 s 4 Choose automatic mode A1 push the A1 button for approx 2 s MANUAL MOD...

Page 90: ...ft XR21S59 CHU User Manual 5B 350 A1 FLAT A2 TIP A3 ISO A4 STO A5 MAN A5 M 6 A1 FLAT A2 TIP A3 ISO A4 STO A5 MAN A6 URB A1 FLAT A2 TIP A3 ISO A4 STO A5 MAN A6 URB A M 7 A1 FLAT A2 TIP A3 ISO A4 STO A5 MAN A1 FLAT A2 TIP A3 ISO A4 STO A5 MAN A M OPEN ...

Page 91: ...n button locks not closed signal light on the control unit is lit when the locks are fully open 6 Opening body locks move the control lever slowly backwards the body locks open locks not closed signal light on the control unit is lit when the locks are fully open 7 Drive the horizontal movement into rear position push the rearmost button in the bottom row on the either side of the control unit hor...

Page 92: ...XR21S59 CHU 92 1 2018 113813003 Hooklift Multilift XR21S59 CHU User Manual 8 A1 FLAT A2 TIP A3 ISO A4 STO A5 MAN A6 URB A1 FLAT A2 TIP A3 ISO A4 STO A5 MAN A6 URB A M 9 LIFT CHECK REVERSE THE LOCKING ...

Page 93: ...ame back keep the control lever in rear position Middle frame turns back main cylinders out frame not down signal light is lit when the middle frame is lifted off the sub frame stop the movement by releasing the control lever when the hook is slightly below the liftfrme gripping bar 9 Gripping the liftframe gripping bar manual mode A5 and automatic mode A1 reverse the truck carefully until the hoo...

Page 94: ...94 1 2018 113813003 Hooklift Multilift XR21S59 CHU User Manual A1 FLAT A2 TIP A3 ISO A4 STO A5 MAN A6 URB A1 FLAT A2 TIP A3 ISO A4 STO 10 A M 11 A1 FLAT A2 TIP A3 ISO A4 STO A5 MAN A1 FLAT A2 TIP A3 ISO A4 STO A M ...

Page 95: ...safety lock is engaged Choose automatic mode A1 push the A1 button for approx 2 s 10 The liftframe comes free from the ground move the control lever slowly forward signal lights locks not closed URB in and frame not down on the control unit are lit main cylinder piston rods move inwards Safety lock of the gripping hook gives way to the gripping bar pushing into the hook release the control lever w...

Page 96: ...U 96 1 2018 113813003 Hooklift Multilift XR21S59 CHU User Manual 12 A1 FLAT A2 TIP A3 ISO A4 STO A5 MAN A6 URB A1 FLAT A2 TIP A3 ISO A4 STO A5 MAN A6 URB A M A1 FLAT A2 TIP A3 ISO A4 STO A5 MAN A5 MAN 13 A M 350 ...

Page 97: ...er piston rods move inwards frame not down signal light on the control unit goes out when the middle frame comes down The speed of lowering the middle frame must be reduced by lowering the engine speed in the last phase of the main cylinder movement The main cylinders are released floating when the middle frame is about 60 mm above the body supports and the final stage of unloading is dampened 13 ...

Page 98: ...XR21S59 CHU 98 1 2018 113813003 Hooklift Multilift XR21S59 CHU User Manual A1 FLAT A2 TIP A3 ISO A4 STO A5 MAN A6 URB A1 FLAT A2 TIP A3 ISO A4 STO A5 MAN A6 URB A5 MAN 14 A M CLOSE ...

Page 99: ...sed should go out 14 Closing body locks body locks close when the control lever is released the locks not closed signal light on the control unit goes out Move and lock the liftframe to the stowage in accordance with sections Moving the liftframe onto the XR21S stowage and Locking the liftframe to the stowage unless the ISO container to be lifted is in the immediate vicinity of the vehicle ...

Page 100: ...rame onto the XR21S equipment s hook XR21S EQUIPMENT IN TRANSPORT POSITION AND THE LIFTFRAME ON THE STOWAGE WHEN STARTING MOVEMENTS Lock grips of the upper parts of the liftframe OPEN CLOSED Locking shafts of the lower parts of the liftframe STOWED position LOCKED postion CROWBAR Temporary STOWED position NOTE 1 ...

Page 101: ...ft may not be detached at this stage 3 Turn the lock grips on the telescopic upper parts on the surface of the lifting frame s vertical beams into OPEN position grips horizontally images 3 It is recommended to keep the lock grips in OPEN position when driving the truck without an ISO container The liftframe is then at its lowest 4 Extract the locking shafts on the lower parts of the liftframe usin...

Page 102: ...102 1 2018 113813003 Hooklift Multilift XR21S59 CHU User Manual 5 6 7 8 6 5 7 8 RATCHET ATTACHED TO FASTENING PIN IN STOWAGE RATCHET IN TEMPORARY POSITION NOTE 2 LOOK OUT FOR THE LURCHING MOVEMENT OF THE LIFTFRAME ...

Page 103: ...king shafts behind the attachment joints of the stowage 7 Turn the locking shafts on the bottom parts of the liftframe to their STOWED position locking plates vertically 8 Disconnect the left ratchet and temporarily place it on the stowage suspension hook so that the ratchet locking pins are in place locking position NOTE 2 After releasing the locking shafts and pins the liftframe will lurch towar...

Page 104: ...P A3 ISO A4 STO A5 MAN 3 A4 1 2 3 4 A1 FLAT A2 TIP A3 ISO A4 STO A5 MAN 3 A5 3 4 Moving to the XR21S hook Let the engine run at idle speed during liftframe movement NOTE Unnecessary use of the main pressure relief valve should be avoided because it may overheat the oil Emergency stop switch ...

Page 105: ...gaging stowage mode A4 Choose mode A4 push the A4 button shortly code A4 is lit on the XR21S equipment control unit display green signal light power on is lit on the stowage control unit If it seems impossible to select the mode and code d019 is displayed on the control unit make sure that the attachment joints of the liftframe ratchets are attached to the stowage NOTE An emergency stop switch can...

Page 106: ... A6 URB A1 FLAT A2 TIP A3 ISO A4 STO A5 MAN A6 URB A1 FLAT A2 TIP A3 ISO A4 STO A5 MAN A6 URB A1 FLAT A2 TIP A3 ISO A4 STO A5 MAN A6 URB A1 FLAT A2 TIP A3 ISO A4 STO A5 MAN A6 URB A1 FLAT A2 TIP A3 ISO A4 STO A5 MAN A6 URB A1 FLAT A2 TIP A3 ISO A4 STO A5 MAN A6 URB A1 FLAT A2 TIP A3 ISO A4 STO A5 MAN A6 URB 5 1 5 2 OPEN EMERGENCY STOP SWITCH UNSTOW BUTTON ...

Page 107: ...ntrol unit display is lit Green signal light power on on the stowage control unit is lit Push the UNSTOW button on the stowage control unit without releasing it 5 1 Opening body locks The body locks open if they are still closed 5 2 The horizontal movement goes in the stow unstow position Starting from Flatrack position 350 mm behind the stow unstow position ...

Page 108: ...ual A1 FLAT A2 TIP A3 ISO A4 STO A5 MAN A6 URB A1 FLAT A2 TIP A3 ISO A4 STO A5 MAN A6 URB A1 FLAT A2 TIP A3 ISO A4 STO A5 MAN A6 URB A1 FLAT A2 TIP A3 ISO A4 STO A5 MAN A6 URB A1 FLAT A2 TIP A3 ISO A4 STO A5 MAN A6 URB A1 FLAT A2 TIP A3 ISO A4 STO A5 MAN A6 URB 5 3 5 4 5 5 ...

Page 109: ...towage actuator turns the stowage hook up and lifts the liftframe from the stowage onto the XR21S gripping hook 5 4 Closing the safety lock of the XR21S gripping hook The safety lock of the XR21S gripping hook locks the liftframe to the gripping hook of the equipment 5 5 The stowage hook turning downwards The stowage actuator turns the stowage hook down ...

Page 110: ...TAINER READY POSITION image 1 If the roller is in the flat rack body change position picture 2 2 Pull the roller locking pins off A 3 Turn the front part of the roller to an upright position Lock it to this position by pushing the shorter locking pin into hole B Push the longer roller locking pin into hole C to the point where you can still turn the roller 4 Turn the roller to the flatrack body ch...

Page 111: ... Let the engine run at idle speed at the beginning and end of movements and while using the locks An ISO container can be loaded in automatic mode A3 because the length of IC and ICC ISO containers 6058 mm doesn t require movements in manual mode outside a safe working area The final stage of loading a container with a heavy load more than 10 t downwards from an angle of approx 20 degrees should b...

Page 112: ... ISO container to be loaded These should be intact straight and properly welded Rundown flat bars may prevent unloading a container as the fronts of the rear rollers sink into the container forklift pockets Check that the TWISTLOCK clasps in the rear beds of the iso container support rollers are fully in the lock housings ...

Page 113: ...arby you can continue according to the instructions in section1 Loading phases If the truck needs to be moved for more than a few meters the under sides of the liftframe must be attached with ratchets on both sides of the vehicle in order to prevent the frame from swaying during transport DO NOT load a container OK Flat bars of ISO container forklift pockets ...

Page 114: ...al 6 6 7 A1 FLAT A2 TIP A3 ISO A4 STO A5 MAN A6 URB 7 6 A 1 2 3 4 A1 FLAT A2 TIP A3 ISO A4 STO A5 MAN A1 FLAT A2 TIP A4 STO A3 ISO A5 MAN A6 URB 5 350 5 1 5 2 5 3 5 1 5 3 5 2 M 5 3 Switch to controlling the equipment with the XR21S control unit OPEN Loading the ISO container ...

Page 115: ...ignal light on the control unit is lit when the locks are open 3 Drive the horizontal movement cylinder in push the rearmost button in the bottom row on the either side of the control unit until the horizontal movement goes to the flatrack home position approx 350 mm from the stow unstow position of horizontal movement AUTOMATIC MODE A3 6 Select automatic mode A3 push the A3 button approx 2 s powe...

Page 116: ...U 116 1 2018 113813003 Hooklift Multilift XR21S59 CHU User Manual 8 A1 FLAT A2 TIP A3 ISO A4 STO A5 MAN A6 URB A 9 A1 FLAT A2 TIP A3 ISO A4 STO A5 MAN A6 URB A A1 FLAT A2 TIP A3 ISO A4 STO A5 MAN 10A 1 2 1 M 2 2 ...

Page 117: ...keep the control lever in rear position middle frame turns back main cylinders out frame not down signal light is lit when the middle frame is lifted off the subframe Stop the movement by releasing the control lever when the container locking pins on the telescopic upper sides of the liftframe are a little above the containers upper corners 10A Driving the horizontal movement outwards only in manu...

Page 118: ...XR21S59 CHU 118 1 2018 113813003 Hooklift Multilift XR21S59 CHU User Manual 11 10B 1 2 A1 FLAT A2 TIP A3 ISO A4 STO A5 MAN 2 A M 1 2 12 2 A1 FLAT A2 TIP A3 ISO A4 STO A5 MAN A6 URB A ...

Page 119: ...xes of the container and the container locking pins are next to the container corner box openings The truck and the ISO container must be exactly parallel 12 Liftframe attached to ISO container 1 1 Reverse the truck so that the control flanges on the lower parts of the liftframe move along the exterior of the lower container corner boxes to the sides of the container Continue reversing until the l...

Page 120: ...rs the lift frame must always be locked at the front by the 2 ratchets mounted to the stowage Because an ISO container locked at all four corner castings is limiting the flexibility of the chassis and can cause high stresses in ratchets and twistlocks off road driving with an ISO container must be performed at low speed ...

Page 121: ...ic upper parts of the liftframe back to locked position grips vertically 3 Check before loading that the TWISTLOCK clasps are inside the lock mechanisms The TWISTLOCK clasp protruding from the lock mechanism grips the lower structures of the loaded container damaging them and a clasp gripping only one side of the container may cause the truck to fall over as the haul is continued 14 Loading an ISO...

Page 122: ...Manual The side of the ISO container must descend between the rear roller control flanges If the front of the container collides too soon with the rear rollers during loading even on even ground the XR21S equipment s approach switches must be readjusted RIGHT WRONG WRONG ...

Page 123: ...he other flange tries to go inside the side profile of the container the container must be lifted again by going into manual mode in between When the handbrake is released the truck moving due to the strength of the XR21S equipment can be steered while the end of the container still rests on the ground A lightly loaded ISO container can under normal conditions be loaded in Automatic mode A1 NOTE W...

Page 124: ...XR21S59 CHU 124 1 2018 113813003 Hooklift Multilift XR21S59 CHU User Manual 16 17 A1 FLAT A2 TIP A3 ISO A4 STO A5 MAN A 18 A1 FLAT A2 TIP A3 ISO A4 STO A5 MAN A 15A A1 FLAT A2 TIP A3 ISO A4 STO A5 MAN M ...

Page 125: ...ugh off the ground not to collide too early with the rear rollers Continue loading the container in automatic mode A3 after lifting it If you performed phase 15A please choose automatic mode A3 again power on signal light on the stowage control unit goes out 16 Middle frame forward move the control lever to front position the main cylinder piston rods move inwards 17 Activate the handbrake when th...

Page 126: ...XR21S59 CHU 126 1 2018 113813003 Hooklift Multilift XR21S59 CHU User Manual 19 A1 FLAT A2 TIP A3 ISO A4 STO A5 MAN A 20 A1 FLAT A2 TIP A3 ISO A4 STO A5 MAN A BODY LOCKS CLOSE ...

Page 127: ...cessively by holding the control lever in the front body locks close when the control lever is released ISO container is not locked with body locks locking it is explained in section 24 the locks not closed signal light on the control unit goes out See chapter Loading a flatrack body sections 18 19 and 20 Please note that the body locks do not lock the ISO container to the XR21S equipment see lock...

Page 128: ...21S59 CHU 128 1 2018 113813003 Hooklift Multilift XR21S59 CHU User Manual 1 21 22 23 1 2 RATCHETS IN STOWAGE DETACH THE RATCHET ATTACHEMENT JOINTS FROM THE STOWAGE AND MOVE THEM TO THE LIFTFRAME BRACKETS ...

Page 129: ... the linch pins in from the outside The length of the ratchets can be adjusted by rotating the middle section with internal threads enough for the pins in the ratchet attachment joints to go into place Prevent the free end of the ratchet from rotating along with the middle section Tighten the middle sections of the container ratchets by rotating them while the ends are attached to the attachment j...

Page 130: ...ecause the length of IC and ICC ISO containers 6058 mm doesn t require movements in manual mode outside a safe working area Only if the ISO container has a heavy load more than 10 t or its floor is extended should the beginning of unloading be done in manual mode A5 in order to prevent the extended container floor from scraping against the XR21S equipment body The first phases of unloading a heavy...

Page 131: ...rom the container corner box 2 The front of the container is attached with ratchets from the liftframe to the XR21S equipment stowage Open these locks after the TWISTLOCKS First rotate the middle sections of the ratchets enough to loosen them Detach the ratchet shafts from the attachment brackets on the liftframe from both sides of the truck Attach the ratchets to fastening pins on the inner sides...

Page 132: ...LAT A2 TIP A3 ISO A4 STO A5 MAN A1 FLAT A2 TIP A3 ISO A4 STO A5 MAN 4 3 1 4 A M BODY LOCKS OPEN APPROX 20 º Unloading an ISO container Follow the instructions in this manual section Unloading a flatrack body which deal with unloading in automatic mode A1 when unloading an empty container or one with a light load from the XR21S equipment ...

Page 133: ...n signal light on the stowage control unit goes out When the control lever is moved back first the XR21S equipment moves the horizontal movement backwards and the middle frame moves back just as depicted in section Unloading a flatrack body describing automatic mode A1 3 Drive the middle frame to an approx 20 degree angle 3 1 move the control lever back main cylinders out frame not down signal lig...

Page 134: ...eave the liftframe attached to the ISO container detach from the container according to the description in section Unloading a flatrack body Note Hook lock can t be opened in A3 automatic mode Use A5 manual mode to open the hook lock If you intend to detach the liftframe from the ISO container and take it elsewhere don t press the safety lock control button as the container reached the ground but ...

Page 135: ...ing the locking shafts using the crowbar if necessary Turn the shafts on both sides of the equipment to 90 upward and fasten them again to the body the locking plates in a STOWED postion 2 Turn the lock grips on the telescopic upper parts of the liftframe back to open position grips horizontally 2 Lifting the upper part of the liftframe from a container PHASES SHOULD BE CARRIED OUT IN AUTOMATIC MO...

Page 136: ...XR21S59 CHU 136 1 2018 113813003 Hooklift Multilift XR21S59 CHU User Manual 3 4 5 A1 FLAT A2 TIP A3 ISO A4 STO A5 MAN A 6 7 8 A1 FLAT A2 TIP A3 ISO A4 STO A5 MAN A BODY LOCKS CLOSE ...

Page 137: ...wn 5 Horizontal movement forward drive the middle frame forward by holding the control lever in the front horizontal movement comes to the front position of container change approx 350 mm from the far front position of horizontal movement 6 Closing body and tipping locks logic closes the body and tipping locks automatically as the control unit is released at the end of the horizontal movement when...

Page 138: ... 138 1 2018 113813003 Hooklift Multilift XR21S59 CHU User Manual 5 5 2 1 1 2 A1 FLAT A2 TIP A3 ISO A4 STO A5 MAN 1 2 3 2 2 EMERGENCY STOP SWITCH 5 2 HORIZONTAL MOVEMENT FORWARD 5 1 THE BODY LOCKS OPEN STOW BUTTON ...

Page 139: ...ent control unit display 2 3 green signal light power on is lit on the stowage control unit If it seems impossible to select the mode and code d019 is displayed on the control unit make sure that the attachment joints of the liftframe ratchets are attached to the stowage 3 Activate the handbrake 4 Engage the hydraulic pump 5 Moving the liftframe from the XR21S gripping hook to the stowage Code A4 ...

Page 140: ...4 STO A5 MAN A6 URB A1 FLAT A2 TIP A3 ISO A4 STO A5 MAN A6 URB A1 FLAT A2 TIP A3 ISO A4 STO A5 MAN A6 URB A1 FLAT A2 TIP A3 ISO A4 STO A5 MAN A6 URB A1 FLAT A2 TIP A3 ISO A4 STO A5 MAN A6 URB A1 FLAT A2 TIP A3 ISO A4 STO A5 MAN A6 URB A2 TIP A4 STO A6 URB A1 FLAT A2 TIP A3 ISO A4 STO A5 MAN A6 URB A1 FLAT A2 TIP A3 ISO A4 STO A5 MAN A6 URB A1 FLAT A2 TIP A3 ISO A4 STO A5 MAN A6 URB A2 TIP A4 STO A...

Page 141: ...f the XR21S gripping hook 5 5 The stowage hook turning downwards The stowage actuator turns its hook down and brings the liftframe onto the stowage The safety lock of the XR21S gripping hook closes as the STOW button is released 5 5a Code d025 is displayed if Stowage in sensor is active but Lift Frame Stowed sensor is not active It will also prevent sliding backwards movement 5 6 The horizontal mo...

Page 142: ...03 Hooklift Multilift XR21S59 CHU User Manual 4 2 1 3 Locking the liftframe to the stowage LOCKING SHAFTS TO TEMPORARY STOWED POSITION LEFT RATCHET INTO LIFTFRAME BRACKETS LOCKING SHAFTS TO STOWED POSITION LIFT FRAME BOTTOM FORWARD ...

Page 143: ...to 180 temporary STOWED position lock plates vertical note leave the whole pin extracted so the liftframe can move in front of the stowage 3 Move the bottom part of the liftframe forward while controlling it with the LH ratchet 4 Turn the locking shafts on the bottom parts of the liftframe to their STOWED position lock plates vertical 5 Attach the right ratchet to the liftframe Move the bottom par...

Page 144: ...1S59 CHU 144 1 2018 113813003 Hooklift Multilift XR21S59 CHU User Manual 4 A1 FLAT A2 TIP A3 ISO A4 STO A5 MAN M 3 A1 FLAT A2 TIP A3 ISO A4 STO A5 MAN A6 URB M 1 A1 FLAT A2 TIP A3 ISO A4 STO A5 MAN M OPEN ...

Page 145: ...amage MANUAL MODE A5 1 Choose manual mode A5 push the A5 button for approx 2 s green signal light power on is lit on the stowage control unit 3 Open the body locks push the bodylocks open button locks not closed signal light on the control unit is lit when the locks are fully open 4 Drive the horizontal movement cylinder in push the rearmost button in the bottom row on the either side of the contr...

Page 146: ...XR21S59 CHU 146 1 2018 113813003 Hooklift Multilift XR21S59 CHU User Manual 7 5 A1 FLAT A2 TIP A3 ISO A4 STO A5 MAN A6 URB M A1 FLAT A2 TIP A3 ISO A4 STO A5 MAN A6 URB 6 6 1 6 2 M ...

Page 147: ...f colliding with the rear rollers stop the movement before colliding and drive the horizontal movement upwards 5 Drive the middle frame back drive the middle frame back by moving the control lever back main cylinders out frame not down signal light is lit when the middle frame is lifted off the subframe MAKE SURE THAT THE GROUND IS FIRM A liftframe support sinking may cause the frame to fall over ...

Page 148: ...XR21S59 CHU 148 1 2018 113813003 Hooklift Multilift XR21S59 CHU User Manual 8 1 8 2 8 3 3 1 2 1 2 A1 FLAT A2 TIP A3 ISO A4 STO A5 MAN A6 URB A1 FLAT A2 TIP A3 ISO A4 STO A5 MAN A6 URB M M ...

Page 149: ...ck opens If it doesn t lift the middle frame slightly by moving the control lever forward Open the safety lock 8 2 Keep the safety lock button pressed and drive the middle frame slightly backwards by moving the control lever backwards Monitor the hook being released from the gripping bar on the liftframe DO NOT TIP THE LIFTFRAME OVER 8 3 Drive the truck forward if the hook has been released from t...

Page 150: ...he bottom row on the either side of the control unit telescope cylinder out horizontal movement comes to the flatrack home position approx 350 mm from the stow unstow position of horizontal movement 11 Closing body and tipping locks logic closes the body and tipping locks automatically as the control unit is released at the end of the horizontal movement when the locks are engaged fully their sign...

Page 151: ...ainer IS NOT allowed THE XR21S REAR ROLLERS WERE NOT DESIGNED FOR TIPPING AN ISO CONTAINER THE ISO CONTAINER SUPPORT ROLLER AXIS AND THE XR21S TIPPING AXIS ARE NOT IN LINE WITH EACH OTHER AS A RESULT TIPPING IS NOT POSSIBLE Always drive in traffic with the middle frame lowered onto the sub frame ...

Page 152: ...XR21S Manufacturer Multilift Raisio Equipment type Technical performance flatrack body max t Technical performance ISO container max t Tipping angle max Working pressure of the hydr system max MPa bar Recommended oil flow rate l min Operating times with oil flow rate X G 56 X l min loading approx s unloading approx s tipping approx s lowering the flatrack body after tipping approx s Weight of the ...

Page 153: ...9 CHU User Manual XR21S56 XR21S59 G mm 5560 5860 h mm 270 H mm 1570 t mm 105 B mm 2800 2850 SL mm 6563 6563 SL G B HM h t H XR21S dimensions BE AWARE When transporting the body with the sliding frame in rear position the hydraulic body lockings must be closed ...

Page 154: ...same time and enable thus a more accurate control at slow speeds and greater oil flow for simultaneous use There is a by pass valve installed on the valve base plate which is adjustable between 16 and 40 l min With this valve part of the oil flow is directed via the second valve of the main cylinders back to the return line and that is the way to obtain the accurate cylinder movements when needed ...

Page 155: ...ional valve 4 Main cylinders second directional valve 5 Free circulation valve 6 Body locking cylinder pressure limiting valve 18 MPa 7 Body locking cylinder pressure limiting valve 18 MPa 8 Hook arm out push pressure limiting valve 18 MPa 9 Main pressure limiting valve 30 MPa 10 Adjustable by pass valve 16 40 l min 11 Pressure measuring nipple 12 Emergency operation push button EMERGENCY OPERATIO...

Page 156: ...nual 1 2 3 4 5 1 Control unit in the cab 2 I O module 3 Valve wiring harness 4 Accessory wiring harness 5 Wiring harness of proximity switches Control devices 2GCC It is not allowed to make any additional connections to the electric system wiring harnesses and valve coils ...

Page 157: ... When the safety lock is open by pneumatic force a sound is produced by the pneumatic cylinder due to the released air Press the button again when necessary Reverse the vehicle so that the hook is below the gripping bar Also see section 11 loading Lift the hook by a movement of the middle frame so that it grips the gripping bar The safety lock is opened when the hook presses down on the gripping b...

Page 158: ...ing the front end of the container to the ground Stop the main cylinder when the container reaches the ground Check that the safety lock is still open If the safety lock has closed it may cause the safety lock or the gripping bar to be damaged when the hook is pressed down on the gripping bar Continue the downward motion of the main cylinders with the safety lock open until the hook is released fr...

Page 159: ...he hook arm moves forward more than 100 mm Tipping is not possible when the hook arm is all the way back During tipping the middle frame is locked to the rear frame by the tipping lock The tipping lock operates automatically according to the movements of the hook arm Locking mechanisms of the hook For safety reasons the tipping loading and unloading operations are secured with various locking mech...

Page 160: ...ck locking rear frame to auxiliary frame During the lowering of a container the rear frame is mechanically locked to the auxiliary frame when the middle frame starts to rise The lock is achieved by the axle tip on the middle frame which slides under the locking stops in the auxiliary frame ...

Page 161: ... lock type is situated in the rear end of the rear frame The locking cylinder steers both locking hooks simultaneously A controlled check valve is fastened to the locking cylinder preventing the cylinder from letting the locks open in case of a broken hose in the hydraulic circuit or an internal leakage in the control valve Thanks to the valve the flatrack body locks stay in the intended position ...

Page 162: ...t Ailluminated lock signal light on the control unit means that the body locks are not fully closed When in traffic no driving or tipping is to be commenced if the light is on Remove the element obstructing the locks or if they are obstructed by the lock pocket in the flatrack body frame beam check that the flatrack body is correctly positioned on top of the hook device Signal light comes on Signa...

Page 163: ...iston rods from buckling The protection circuit comprises a tilt indicator and a pressure relief valve If the tilt is greater than set angle value the working pressure is restricted to 11 MPa 110 bar and the backwards movement of the container may stop If this does take place check that the movement of the platform rearward is free from obstructions Tilt indicator Tilt indicator ...

Page 164: ...r problems with the equipment contact the nearest Multilift service point Repairs related to these may be carried out only by the professional and trained personnel Especially the electrical system and the hydraulics are such which require specialised competence Wash the equipment carefully with low pressure washer before inspection and service Dry and check all electrical components after washing...

Page 165: ...ll the spare parts must conform with the technical requirements of Multilift The best way to ensure this is to use the original Multilift spare parts The safe and easy accomplishment is best achieved by using the correct and sound tools Note the service and inspection periods mentioned in this instruction and the replacement needs of parts which have been noted in connection with the equipment ins...

Page 166: ...ple with a warning sign If there are several persons involved in the service work at the same time the one having the ignition key must inform everybody if for example the truck engine is started or the hooklift functions are used If the work area is under the tipping frame the equipment must be moved to loading position Hooklift in rear position If the work is done under the middle frame the equi...

Page 167: ...ompleted BE AWARE Never move the middle frame or the rear frame by means of hydraulics against the tipping support The equipment cylinders are powerful enough to break the support or the frames and there is a great risk of personal injury Stop the movement of the main cylinders immediately when the frame reaches the support Stop the truck engine always when doing service work under the raised fram...

Page 168: ...ropriate manner noting all environmental rules and regulations Before commencing any service or repair work ensure that the vehicle is standing on an even surface with the hand brake engaged Remember to follow appropriate work safety and environmental instructions Record all service and repair work and any special matters which have appeared during the job Service table Daily 1 1 Check the safety ...

Page 169: ...uipment carefully 3 2 Lubricate all the lubrication points 3 3 Check all the safety functions without a container 3 4 Check all frame constructions for possible damages and ensure their correct functioning 3 5 Check the tightness and condition of all fastening bolts 3 6 Check the gripping hook condition and wear 3 7 Check the whole hydraulic system for leaks and damages 3 8 Check the condition of ...

Page 170: ...yes Do not carry out work on hydraulic components under a raised frame Use always a mechanical support Do not remove any hydraulic components before supporting the frames and releasing hydraulic system pressure Pipe connections hose lengths and materials must conform with the Multilift requirements Use original Multilift spare parts or ensure otherwise that the components correspond with the highe...

Page 171: ...nnels and containers free of dust Always use clean towels or preferably high quality tissue Before removing the hydraulic system components clean the surrounding areas carefully with steam or fat removal agent Checking the oil level When the middle frame and the hook arm are in operating position the oil level should be in the middle of the sight glass Checking the return filter Use a dirt indicat...

Page 172: ... a sign of too little oil or of a leak in suction line solid particles indicate a component damage or old oil air is a sign of oil ageing as a result of overheating If you notice any of the above symptoms in oil change it according to the following instructions Attention Hydraulic oils especially mineral oils are hazardous to environment Therefore follow all regulations pertaining to collecting an...

Page 173: ...hydraulic oil 1 Check that all piston rods of the cylinders are in retracted position 2 Completely empty the oil tank via the drain plug 3 Change the return filter 4 Fill the tank with new oil via the return filter 5 Check the air filter Hydraulic oil specifications Quality classes ISO 6743 4 type HV or DIN 51524 part 3 type HVLP or Swedish SMR standard for hydraulic oil SHS Degree of cleanliness ...

Page 174: ...uestion A lower ambient temperature is the same as the lowest starting temperature Note Vegetable based bio oils are not allowed to be used Only synthetic environment friendly oils that meet the above mentioned requirements are allowed Note Do not mix different oil qualities Mixing of different oils weakens generally their characteristics If it is necessary to use an alternative oil check with the...

Page 175: ... with a suitable flushing agent 2 Completely empty the hydraulic cylinders tubes hoses and the suction hose to the pump 3 Change the return filter 4 Fill the tank with new oil via the return filter Operate all cylinders carefully to ensure that they will be filled with oil Ensure that the pump is filled all the time Fill up the tank before it gets empty 5 Drive for 2 or 3 days 6 Check that all pis...

Page 176: ...e approx 0 5 m raised moving of hook arm is not possible during tipping hook arm cannot be moved when the hydraulic body locks are closed body locks signal light is lit when the locks are not closed Check the functioning of the load holding valves with a loaded container let the hooklift stay with the container raised for 5 minutes and check that the tipping device has not descended by itself fig ...

Page 177: ...XR21S59 CHU 177 1 2018 113813003 Hooklift Multilift XR21S59 CHU Service Manual Loading position Tipping device raised ...

Page 178: ... of piston rods If the chromium surface of the rod is damaged especially if the scratches are longitudinal the rod or the whole cylinder must be changed wear rate of the gripping hook The original thickness of the hook must not be worn more than 10 wear rate of the slide pads The maximum wear of the slide pads is 3 mm but already a clearance of over 1 mm between the hook arm and the middle frame r...

Page 179: ...U 179 1 2018 113813003 Hooklift Multilift XR21S59 CHU Service Manual Мin 60 mm Мin 70 mm Мin 10 mm Мax 100 mm s min 75 mm s min 85 mm XR S pneum Hook wear limits Slide pads in middle frame Slide pads in hook arm ...

Page 180: ...l the safety instructions and regulations related to electric work must be noted Use always only original electric components It is not allowed to make any additional connections to the electric system wiring harnesses and valve coils Emergency operation CAUTION Internal safety functions of the device do not work in manual control mode Therefore be especially careful when carrying out the movement...

Page 181: ...ress down the button located at the end of valve for needed direction 101 or 114 and hold it down 2 Press down the button located at the end of free circulation valve 108 3 Release the buttons when you would like to stop the movement Note The valve stem return spring 101 or 114 is rather rigid and requires effort to push the button to the bottom You can use the emergency movement lever MU111568801...

Page 182: ...the cab controller are the access buttons to the software Normally these buttons are identified as body locks closed and body locks open The procedure of setting the illumination strength of the backlight is the following Press the first row buttons simultaneously for 10 seconds C002 can be seen in the display while pressing the buttons System will make 2 short beeps and all red LEDs will be short...

Page 183: ...rwards or backwards to adjust the active illumination strength between 0 100 When you have the desired illumination level press the top right button locks open to save the value Press the hook safety lock button to show the LO in the display and wait until a value is shown Move the joystick forwards or backwards to adjust the inactive illumination strength between 0 100 When you have the desired i...

Page 184: ...n Press both top buttons for 5 seconds to exit the software and return back to normal operation The text OFF will be shown for a couple of seconds in the display The backlight illumination will dim after 30 seconds of inactive period and light up when joystick is moved or any button pressed If both HI and LO are set to same value there is no difference in the brightness Press 5 s ...

Page 185: ...he components or power feed Usually there is a short circuit causing the error Conflicts can be less critical and usually there is a missing signal from a switch causing the error Diagnoses are usually caused by fault operation or missing signal from proximity switch If there are more than one error code in the system the display in control unit is showing them in sequence and should be read all b...

Page 186: ...ING IS ON EMERGENCY STOP IS ON SERVICE TOOL ACTIONS ONGOING SOFTWARE LOADING DOWNLOADING ETC CONFLICT CODE C001 C020 SEE CODES ON FOLLOWING PAGES IN THE CHAPTER ERROR CODES CONFLICTS DIAGNOSTIC CODE D001 D028 SEE CODES ON FOLLOWING PAGES IN THE CHAPTER ERROR CODES DIAGNOSES FAILURE CODE F001 F081 SEE CODES ON FOLLOWING PAGES IN THE CHAPTER ERROR CODES FAULTS CONTROL UNIT ERROR CODE 01 01 99 00 SEE...

Page 187: ... ON CONTROL BOX CONTROL BOX INTERNAL ERROR 2 REPLACE CONTROL BOX IF ERROR REPEATS F003 VALUES FROM PRESSURE SENSOR NOT LEGAL 2024 PRESSURE SENSOR CHECK CONNECTION REPLACE SENSOR NO ACTION F004 INTERNAL PARAMETER ERROR 2024 PARAMETER CHECK PARAMETERS REPLACE MAIN BOX NO ACTION F005 CAN BUS NOT ABLE TO COMMUNICATE WITH 2024 ANY POSITION TIME OUT 1 CHECK BOX CAN BUS WIRE REPLACE IF NECESSARY NO ACTIO...

Page 188: ...LES F014 Main cylinder in 1 voltage when not controlled 2024 Voltage when not controlled CHECK THE CABLES F015 Main cylinder in 2 short cut 2024 SHORT CIRCUIT CHECK THE CABLES F016 Main cylinder in 2 voltage when not controlled 2024 Voltage when not controlled CHECK THE CABLES F017 Main cylinder out 1 short cut 2024 SHORT CIRCUIT CHECK THE CABLES F018 Main cylinder out 1 voltage when not controlle...

Page 189: ...CABLES F024 Sliding backwards voltage when not controlled 2024 Voltage when not controlled CHECK THE CABLES F025 Sliding forwards short cut 2024 SHORT CIRCUIT CHECK THE CABLES F026 Sliding forwards voltage when not controlled 2024 Voltage when not controlled CHECK THE CABLES F027 Fast speed short cut 2024 SHORT CIRCUIT CHECK THE CABLES F028 Fast speed voltage when not controlled 2024 Voltage when ...

Page 190: ...HE CABLES F034 Bodylocks Out voltage when not controlled 2024 Voltage when not controlled CHECK THE CABLES F035 Urb In short cut 2024 SHORT CIRCUIT CHECK THE CABLES F036 Urb In voltage when not controlled 2024 Voltage when not controlled CHECK THE CABLES F037 Urb Out short cut 2024 SHORT CIRCUIT CHECK THE CABLES F038 Urb Out voltage when not controlled 2024 Voltage when not controlled CHECK THE CA...

Page 191: ...4 Tilting Forwards voltage when not controlled 2024 Voltage when not controlled CHECK THE CABLES F045 Tilting Backwards short cut 2024 SHORT CIRCUIT CHECK THE CABLES F046 Tilting Backwards voltage when not controlled 2024 Voltage when not controlled CHECK THE CABLES F047 Bogie Blocking On short cut 2024 SHORT CIRCUIT CHECK THE CABLES F048 Bogie Blocking On voltage when not controlled 2024 Voltage ...

Page 192: ... Out short cut 2024 SHORT CIRCUIT CHECK THE CABLES F054 Additional Hydraulics1 Out voltage when not controlled 2024 Voltage when not controlled CHECK THE CABLES F055 Hook lock short cut 2024 SHORT CIRCUIT CHECK THE CABLES F056 Hook lock supply voltage 2024 Voltage when not controlled CHECK THE CABLES F057 Buzzer short cut 2024 SHORT CIRCUIT CHECK THE CABLES F058 Buzzer supply voltage 2024 Voltage ...

Page 193: ... controlled CHECK THE CABLES F065 Additional Hydraulics2 In short cut 2024 SHORT CIRCUIT CHECK THE CABLES F066 Additional Hydraulics2 In voltage when not controlled 2024 Voltage when not controlled CHECK THE CABLES F067 Additional Hydraulics2 Out short cut 2024 SHORT CIRCUIT CHECK THE CABLES F068 Additional Hydraulics2 Out voltage when not controlled 2024 Voltage when not controlled CHECK THE CABL...

Page 194: ...controlled 2024 Voltage when not controlled CHECK THE CABLES F077 SUPPLY VOLTAGE FOR CONTROL UNIT SHORT CIRCUIT 2024 CONTROL UNIT SHORT CIRCUIT CHECK POWER WIRES BETWEEN 2024 MODULE AND CONTROL UNIT F078 SUPPLY VOLTAGE FOR CONTROL BOX WHEN NOT CONTROLLED 2024 Voltage when not controlled CHECK THE CABLES F079 TILT SENSOR VALUES NOT LEGAL OR NOT CONNECTED 2024 Tilt sensor middle frame out of range C...

Page 195: ...R SWITCH 2 C004 BOTH INPUTS PRESENT AT CONTROL BOX CONTROL BOX ROCKER SWITCH CONFLICT 3 REPLACE ROCKER SWITCH 3 C005 BOTH INPUTS PRESENT AT CONTROL BOX CONTROL BOX ROCKER SWITCH CONFLICT 4 REPLACE ROCKER SWITCH 4 C006 BOTH INPUTS PRESENT AT CONTROL BOX CONTROL BOX ROCKER SWITCH CONFLICT 5 REPLACE ROCKER SWITCH 5 C007 MIDDLE FRAME DOWN SENSOR IS 1 AND REAR FRAME IS 0 HOOKLIFT INPUTS CONFLICT 1 CHEC...

Page 196: ...RECTIONAL SWITCH CENTER TAPP IN MIDDLE CONTROL BOX JOYSTICK CONFLICT CALIBRATE JOYSTICK CHECK WIRES REPLACE IF NECESSARY C015 JOYSTICK HIGH VALUE WITHOUT DIRECTIONAL SWITCH CENTER TAPP NOT IN MIDDLE CONTROL BOX JOYSTICK CONFLICT CALIBRATE JOYSTICK CHECK WIRES REPLACE IF NECESSARY C016 JOYSTICK LOW VALUE WITHOUT DIRECTIONAL SWITCH CENTER TAPP NOT IN MIDDLE CONTROL BOX JOYSTICK CONFLICT CALIBRATE JO...

Page 197: ...N WRONG POSITION OPEN CLOSE THE BODYLOCKS OR CHECK SENSORS d003 TIPPING LOCK IS OPEN TIPPING LOCK IN WRONG POSITION CHECK THE TIPPING LOCK CLOSED SENSOR OPEN THE LOCKS SLIDE FWD NO HOOKLIFT FUNCTION d004 TIPPING LOCK IS CLOSED TIPPING LOCK IN WRONG POSITION CHECK THE TIPPING LOCK CLOSED SENSOR CLOSE THE LOCKS SLIDE BWD NO HOOKLIFT FUNCTION d005 TIPPING LOCK IS IN MIDDLE POSITION TIPPING LOCK IN WR...

Page 198: ... d013 REAR FRAME IS DOWN REAR FRAME IN WRONG POSITION d014 ARM IS NOT IN BACK POSITION TELESCOPIC TILTING ARM IN WRONG POSITION SLIDE TILT BWD OR CHECK THE HORIZONTAL MOVEMENT BACK SENSOR d015 ARM IS IN BACK POSITION TELESCOPIC TILTING ARM IN WRONG POSITION d016 PULL LIMITER IS ACTIVE PULL LIMITER IS ACTIVE SLIDE TILT BWD OR CHECK THE PULL LIMITER SENSOR NO SLIDE FWD d017 CRANE BODY IS ACTIVE CRAN...

Page 199: ...N d021 URB IS OUT URB IN WRONG POSITION d022 URB IS IN MIDDLE POSITION URB IN WRONG POSITION d023 Not in use d024 Not in use d025 LIFT FRAME NOT STOWED LIFT FRAME STOWED SENSOR INACTIV SLIDING BWD IS PREVENTED d026 STOWAGE IS NOT IN OPERATE STOWAGE HOOKS IN STOWAGE HOOKS ARE NOT IN d027 HOOKLIFT IS DISABLED ROAD MAT IS ON ROAD MAT FUNCTION IS ON SWITCH THE ROAD MAT FUNCTION OFF NO HOOKLIFT FUNCTIO...

Page 200: ...OT IN FRONT OPERATE SLIDE FRAME TO FRONT SLIDE FRAME TO MUCH BACK d042 TILTING ARM IS NOT MOVING IN A5 MODE WHEN MIDDLE FRAME IS DOWN OR AUTOMATIC MODES A1 A2 CANNOT BE ACTIVATED WHEN MIDDLE FRAME IS UP AND SLIDE ISN T IN BACK POSITION SLIDE FRAME SLIDE NOT IN BACK POSITION OPERATE SLIDE FRAME FULLY BACK SLIDE FRAME IS NOT FULLY BACK OR THE SENSOR IS NOT ACTIVE d044 SLIDE NOT FUNCTIONING SLIDING O...

Page 201: ...LY WAIT UNTIL THE SYSTEM HAS STARTED 01 04 MEDIUM RAM MEMORY FAILURE INCORRECT RAM AND OR HARDWARE IDENTIFICATION ERROR DISPLAYED ON DISPLAY CAN MODULE SWITCHED TO PRE OPERATIONAL STATE AND SYSTEM WILL SELF RESET AUTOMATICALLY WAIT UNTIL THE SYSTEM HAS STARTED ERROR CODE 1 2 CATEGORY DESCRIPTION CAUSE ACTION Error codes control unit POSSIBLE ERRORS INSIDE CONTROL UNIT WHEN INTERNAL OR COMMUNICATIO...

Page 202: ...ELF RESET AUTOMATICALLY WAIT UNTIL THE SYSTEM HAS STARTED 08 03 MEDIUM CAN PHYSICAL LAYER ERROR BAD COMMUNICATION TRANSMISSION ERROR DISPLAYED ON DISPLAY CAN MODULE SWITCHED TO PRE OPERATIONAL STATE AND SYSTEM WILL SELF RESET AUTOMATICALLY WAIT UNTIL THE SYSTEM HAS STARTED 08 04 MEDIUM CAN MESSAGE LENGTH ERROR CAN MESSAGE LENGTH IS TOO LONG ERROR DISPLAYED ON DISPLAY CAN MODULE SWITCHED TO PRE OPE...

Page 203: ...DETECTED ON JOYSTICK ERROR DISPLAYED ON DISPLAY JOYSTICK FUNCTIONALITY WILL BE REMOVED UNTIL NEXT POWER CYCLE 17 01 SEVERE LOW POWER SUPPLY LOW POWER SUPPLY BELOW 8 5 VDC ERROR DISPLAYED ON DISPLAY SYSTEM SWITCHED TO ERROR STATE SYSTEM MUST BE POWER CYCLED 17 02 SEVERE HIGH POWER SUPPLY HIGH POWER SUPPLY ABOVE 36 0 VDC ERROR DISPLAYED ON DISPLAY SYSTEM SWITCHED TO ERROR STATE SYSTEM MUST BE POWER ...

Page 204: ...XR21S59 CHU 204 1 2018 113813003 Hooklift Multilift XR21S59 CHU Service Manual 120 119 313 316 317 318 319 320 321 115 114 125 1 125 2 126 XR S SENSORS ...

Page 205: ... 115 Stowage out Ø18 NO 125 1 Ratchet left Ø18 NO 125 2 Ratchet right Ø18 NO 126 Liftframe on the stowage Ø30 NO LUBRICATION Lubricate all the lubrication points at max 3 month intervals Amore recommended lubrication interval would be 1 month Note The hooklift equipment contains plastic surface slide bearings Use LITHIUM based general lubrication grease EP2 Molybden based lubricant shortens the se...

Page 206: ...XR21S59 CHU 206 1 2018 113813003 Hooklift Multilift XR21S59 CHU Service Manual 1 2 3 4 5 6 7 8 9 10 11 12 XR21S Lubrication points ...

Page 207: ... Rear frame bearing 1 1 6 Rear rollers 2 2 7 Hooks of the hydraulic locks if necessary spray 8 Hook arm slide tube if necessary spray 9 ISO container support rollers l r 5 5 10 ISO container support roller shafts l r 1 2 1 2 11 Stowage hook shaft 1 1 12 Ends of liftframe ratchets l r 1 1 1 1 Total number of nipples 36 38 It is recommended to use a drying material for example teflon or a silicon sp...

Page 208: ... EC Annex II part 1 sub A We Cargotec Finland Oy Multilift Nesteentie 36 FI 21200 Raisio Finland declare on our sole responsibility that the Ground Level Demountable Equipment Mark Type Serial number Manufacturing year complies with the provisions of the machinery directive 2006 42 EC also complies with the provisions of the directive on electromagnetic compatibility 2004 108 EC as amended ...

Page 209: ...en read through as witnessed below Product operation instructions and safety instructions have been received ____________________________________ Purchaser Installation and delivery service carried out according to the manufacturer s instructions ________________________________________ Seller Body builder To ensure that the warranty applies this delivery card should be received by the manufacture...

Page 210: ...ea wherever cargo is on the move Cargotec s daughter brands Hiab Kalmar and MacGregor are recognised leaders in cargo and load handling solutions around the world Cargotec s global network is positioned close to customers and offers extensive services that ensure the continuous reliable and sustainable performance of equipment Cargotec Finland Oy reserves all rights for this user manual ...

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