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Summary of Contents for maxilift M50 Series
- Page 1 Mod. USE AND MAINTENANCE MANUAL USE AND MAINTENANCE MANUAL USE AND MAINTENANCE MANUAL USE AND MAINTENANCE MANUAL USE AND MAINTENANCE MANUAL Code MD.0.136 GB Edition 03/07...
- Page 2 Stabilizer Back load attachment Quick fitting kit PRELIMINARY INFORMATION Operator’s and Maintenance Manual of MAXILIFT M50 truck loader. Manual code: MD.0.136 GB This manual is valid starting from serial no: ....Manufacturer: NEXT HYDRAULICS S.r.l. Via Mediterraneo 6, Boretto (RE)-ITALY In this manual the word “Manufacturer”...
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Page 3: Table Of Contents
INDEX FOREWORD -------------------------------------------------------------------------------------------- Page -- 1 Remarks ------------------------------------------------------------------------------------------------ “ ----- 1 HOW TO CONSULT THE MANUAL ------------------------------------------------------------------- “ ----- 1 Instructions ------------------------------------------------------------------------------------------------ “ ----- 1 CRANE IDENTIFICATION -------------------------------------------------------------------------------- “ ----- 2 Identification data -------------------------------------------------------------------------------------------- “ ----- 2 3.3.1 Name plate description ------------------------------------------------------------------------------------ “ ----- 2 Main crane components identification ------------------------------------------------------------------ “... - Page 4 Accessories -------------------------------------------------------------------------------------------- Page - 21 6.7.1 Electrical winch ---------------------------------------------------------------------------------------------- “ ---- 21 6.7.2 Manual winch ------------------------------------------------------------------------------------------------ “ ---- 23 6.7.3 Stabilizer kit ------------------------------------------------------------------------------------------------ “ ---- 24 6.7.4 Back load attachment -------------------------------------------------------------------------------------- “ ---- 24 6.7.5 Quick fitting kit ----------------------------------------------------------------------------------------------- “ ---- 25 Main operating errors --------------------------------------------------------------------------------------- “...
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Page 5: Foreword
FOREWORD Remarks This manual gives the guidelines for a correct, safe usage of the loader and its rational maintenance. When daily and constantly applied, these guidelines ensure long service life with minimum maintenance costs, high performance of the loader and good commercial value after years. Moreover, most of the frequent accidents during operation and servicing are avoided. -
Page 6: Crane Identification
CRANE IDENTIFICATION Identification data Every loader is identified by its serial number and name of the model written on the plate riveted on the column (Pict. 1). 3.1.1 Name plate description Crane model Serial number Year of manufacturing Lifting class Max SWL [kg] Max SWL [lbs] ATTENTION... -
Page 7: Crane Composition
Finally, the operating system is the hydraulic or electro-hydraulic system transmitting the movement to the actuators (cylinders). It is consisting of a pump (electric or manual) and control system (button strip or hydraulic valve bank). In this type of crane the slewing support and column assembly make up the slewing system, which can be of three types: thrust rotation;... -
Page 8: Accessories
3.4 Accessories According to crane use, there are accessories whose application is not compulsory, but which are essential in some cases. These are: Manual winch Electrical winch Back load attachment Stabilizer Quick fitting system Pict. 4 Winch (see chap. 6.7.1 for electrical winch and 6.7.2. for the manual winch); Stabilizers (see chap. -
Page 9: Commissioning
COMMISSIONING Check list before the first commissioning Check that the crane is complete of: CE declaration of conformity of the crane manufacturer; CE declaration of conformity of the crane installing workshop or self-certification of installation performed according to Manufacturer’s installation instructions; Operator’s and maintenance manual;... -
Page 10: Rules Concerning Safety In The Traffic
6 6 6 6 6 5 5 5 5 5 7 7 7 7 7 8 8 8 8 8 13 13 12 12 3 3 3 3 3 MAX Kg200 9 9 9 9 9 1 1 1 1 1 11 11 12 12 16 16... -
Page 11: Operating Instructions
OPERATING INSTRUCTIONS Daily check list Check the existence of oil leaks; Check the correct working of the load limiting device, if installed (see on relevant paragraph); Check oil level and fill up if necessary; Check the good conditions of hoses and piping; Check the good conditions of the winch rope;... - Page 12 Never operate the crane without having checked that the outriggers are well positioned on firm ground. If necessary, their bearing area must be increased with additional pads. The truck stability relies very much on the working conditions! When the ground under the outrigger pads is sinking, their bearing area must be increased. The crane Manufacturer can supply additional plates on request with increased area.
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Page 13: Ten Basic Rules For The Safe Loader Operator
Always extend fully the outrigger beams to their working position (i.e.: maximum opening position), when foreseen, to grant the maximum stability of the vehicle and safety. ATTENTION The outrigger beams are in their working position when the yellow band existing on every beam can be entirely seen. -
Page 14: Thrust Slewing System
6.6.1 Thrust rotation system Operation: The thrust rotation system is so called because the operator performs column rotation by pushing on Braking Screw crane arm. The system is supported by a friction block braking device (pict. 6). It is consisting of a block lever Ring which is locked by a lever on a plastic ring fixed on... -
Page 15: Hydraulic Slewing System
6.6.3 Hydraulic slewing system Operation: This system is fulfilled with a worm/crown gearing protected by a casing and operated by an hydraulic motor (pict. 8). Such motor is energized by the operating system consisting of an electro-hydraulic power unit and a control valve bank. Casing Use: To start the system you have to:... -
Page 16: Boom Lifting System By Hydraulic Cylinder
Use: To lead the boom to working position the operator has to: set the boom almost horizontally; pull out the manual extensions (if necessary, and in case of manual extension boom system); lift the boom assembly to the desired angle, choosing among those allowed by the mechanic strut holes. To adjust the mechanic strut length you have to: support the boom without any load hanging;... -
Page 17: Two Manual Extensions Boom System
6.6.6 Two manual extensions boom system Operation: With this system (pict. 11), the extensions can only be manually pulled out, fixing the boom assembly outreach by inserting the lock pins into the properly aligned holes. Use: Place the boom horizontally. To pull out both extensions, proceed as follows: pull out the lock pin A holding it by the handle, and turn it to release it from relevant safety hook on the boom;... -
Page 18: Boom System With 1 St Hydraulic And 2 Nd Manual Extensions
DANGERS If you wish to pull out only the 2 extension with the 1 one completely retracted, it is necessary to lock the assembly by inserting the lock pin only in the hole on the boom, and not in the hole of the 1 extension, otherwise the system would not be locked. -
Page 19: Hydraulic Operating System By Hand Pump For Lifting Cylinder
DANGERS Exclusively use the lock pin (and not the fingers!) to align the profiles’ slots. Before lifting a load, make sure the lock pin is correctly inserted; a wrong lock pin insertion may cause its breaking. The lock pin extraction with the boom assembly in leaning position increases shearing risk. The lock pin non-insertion or breaking cause an uncontrolled sliding of the 2 extension. -
Page 20: Hydraulic Operating System By Hand Pump For Lifting And Extension Cylinders
6.6.9 Hydraulic operating system by hand pump for lifting and extension cylinders Operation: The system (pict. 14) is consisting of a manually operated hydraulic pump and a two functions control valve bank with levers equipped with automatic return into neutral position. -
Page 21: Hydraulic Operating System By Hand Pump For Extension Cylinder
6.6.10 Hydraulic operating system by hand pump for extension cylinder Operation: The system (pict. 15) is consisting of manually operated hydraulic pump and a two functions control valve bank with one lever equipped with automatic return into neutral position. The valve bank controls the boom extension. -
Page 22: Electro-Hydraulic Operating System By Power Unit With Two Functions For Lifting And Extension Cylinders
CORRELATED SAFETY DEVICES The power unit overpressure valve, calibrated at 170 bar, Button strip prevents lifting Raising weights exceeding button the allowed ones. The sink rate control valve on the lifting Casing Cable cylinder controls load’s lowering in case hose Lowering Lifting cylinder breaking. -
Page 23: Electro-Hydraulic Operating System By Power Unit With Two Functions For Slewing And Lifting Cylinder
After use: Fully retract the extensions and lock the 2 one correctly; put the crane back within its min. overall volume position; extract the key from the battery disconnector and put it back in a safe and protected place. ATTENTION If you wish to extend the boom hydraulically once the max. -
Page 24: Electro-Hydraulic Operating System By Power Unit With Three Functions For Slewing, Lifting And Extension Cylinders
DANGERS Make sure that the rotation stop prevents excessive tractive forces on hydraulic hoses. CORRELATED SAFETY DEVICES The control valve overpressure valve, calibrated at 170 bar, prevents lifting weights exceeding the allowed ones. The overcenter valve on the lifting cylinder controls load’s lifting and lowering in case the slewing function is operated simultaneously to the lifting function. -
Page 25: Electrical Winch
Hoses Motor start Battery button disconnector Extension Valve bank boom-out Boom levers lowering Extension Right boom-in slewing Levers Protection Boom raising Left Casing slewing Pict. 19 Accessories 6.7.1 Electrical winch Operation: The electrical winch (pict. 20) is a cable lifting device applied on the crane boom by proper brackets, which along with the transmission, hooking and safety devices, becomes an integral part of it. - Page 26 IMPORTANT Cable Always keep the rope tensioned, avoiding leaning the counter weight Snub pulley when hooking the load. This prevents turns loosening on the winch drum, and consequently the rope damaging. Pulley holding side lift the load of a few centimetres using Wing nut the winch, and immediately release the lifting button to check the winch brake...
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Page 27: Manual Winch
6.7.2 Manual winch Operation: To lift the load, turn the crank clockwise. To lower the load turn the crank counter clockwise. Give a sharp counter clockwise blow to the crank handle to facilitate rope unwinding without load. Use: To start the system, it is necessary to: Apply the pulley attachment (pict. -
Page 28: Stabilizer Kit
6.7.3 Stabilizer kit Hooking Max. Commissioning: device extension Pull out the stabilizer rod hole from the base unlocking the Main automatic hooking device, beam Mounting and slip it in with the Plate stabilizer leg downwards, lifting and immediately releasing the hooking device until it automatic Extendable locks into the hole which... -
Page 29: Quick Fitting Kit
This accessory cannot be used: when the electrical or manual winch Hexagonal kits are used, because the device is tube applied on an hexagonal tube which is to be slipped into the end of the 2 extension, fixing it by its safety lock pin in place of the pulley attachment Spring catch required for the winch kit;... -
Page 30: Main Operating Errors
Antitheft device When the crane is locked, we suggest to apply the two padlocks supplied with the kit to the proper holes of the mobile hooking pivots. In order to apply the padlocks to such holes it is essential that both nuts are fully screwed. Checking before fixing the crane: Check he main structural parts involved by the fixing operation (hooking profiles of the slewing support, mobile hooking, fixed hooking) do not show any deformation or welding with flaws. -
Page 31: Maintenance And Checking
MAINTENANCE AND CHECKING Protection and storage 7.1.1 Short shutdowns Wash and clean the loader, lubricate all the parts provided with grease nipples and the worm screw gearing. ATTENTION Never wash the loader with chemical products or high pressure water jets, as they can cause the detaching of the stickers water entering inside the electrical components and the slewing case. - Page 32 Every maintenance work has to be carried out with care. Do not delay repair or maintenance works on the crane. Repair works must be assigned only to qualified, skilled people. The recommended procedures of repair and maintenance must always be followed carefully. If necessary ask for a preventive authorization.
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Page 33: Maintenance Schedule
Maintenance schedule 8.3.1 Check list before a working session Check the level of hydraulic oil in the tank. Check the hoses, the fittings and all the other components of the hydraulic system, in order to eliminate any possible source of oil leak. General verification of crane operation and integrity. -
Page 34: Oil Level Checking
8.4.1 Oil level checking The oil level must be checked periodically by the fill up cover of the hand pump, and visually through the transparent tank of electro-hydraulic power unit, with the crane in rest position and the truck on flat ground. If necessary, top up with hydraulic oil filling up through the cover. -
Page 35: Worm Gear Assembly Control
8.4.4 Worm gear assembly control It is important to check that the worm gear reducer has a correct axial backlash. This can be made with the crane at standstill and the boom in horizontal position. Pushing the boom aside on the left and on the right by hand, you can notice if the axial backlash between the worm screw and the worm gear is too great. -
Page 36: Greases And Oils Reference Table
Greases and oils reference table BRAND TOTAL MOBIL ESSO AGIP GREASE MULTIS MOBILGREASE BEACON GR MU ATHESIA ENEGREASE LR MP GREASE MULTIS MOBILGREASE BEACON GR MU ATHESIA ENERGREASE LR MP HYDRAULIC OIL AZOLLA NUTO HYDRUS HENERGOL ZS 46• H 46• 46•... -
Page 37: Technical Data
TECHNICAL DATA Crane overall dimensions Winch overall dimensions Type 1180 1340 1160 1360 Pict. 30 Stabilizer overall dimensions Pict. 31 Via Mediterraneo, 6 - 42022 - Boretto - Reggio Emilia - Italy - 33 - Tel. +39 - 0522-96 30 08 - Fax +39 - 0522-96 30 39 info@maxiliftcrane.com... -
Page 38: Load Chart Tables
Load chart tables 9.4 Technical specifications 9.4.1 Technical data table Lifting capacity [kNm] [ft*lbs] 3688 Max. lifting height from crane base 3.40 [ft] 11.15 Max. working slope [°] Max. working pressure [bar] [p.s.i.] 2465.6 Electro-hydraulic power unit supply voltage Max. absorption electro-hydraulic power unit Hydraulic oil tank capacity Max. -
Page 39: Table Of Weights For Foreseen Crane Versions
9.4.2 Table of weights for foreseen crane versions VERSION Basic crane weight Crane weight with winch [kg] [lbs] [kg] [lbs] M50.2M MSF VE (VM) 138.6 M50.2M MLF VE (VM) 156.2 M50.2H PSF VE (VM) 180.4 M50.2H PLF VE (VM) M50.2M PSH 167.2 M50.2M PLH 162.8... -
Page 40: Hydraulic Diagram Hand Pump + Valve Bank For Lifting And Extension Cylinders
10.2 Hydraulic diagram hand pump + valve bank for lifting and extension cylinders 1 Hand pump 2 Pump 3 Valve bank 4 Lifting cylinder 5 Compensated throttle 6 Sink rate control valve 7 Double acting lock valve Calibration overpr. valve 170 bar 8 Extension cylinder 9 Check valve 10 Oil tank... -
Page 41: Electro-Hydraulic Diagram Motor Pump For Lifting Cylinder
10.4 Electro-hydraulic diagram motor pump for lifting cylinder Calibration overpr. valve 170bar 1 Motor pump 8 Overpressure valve 2 Pump 9 Check valve 3 Lifting cylinder 10 Boom raising button 4 Compensated throttle 11 Boom lowering button 5 Sink rate control valve 12 Relay 6 Oil tank 13 Dump solenoid valve... -
Page 42: Electro-Hydraulic Diagram Motor Pump For Slewing And Extension Cylinder
10.6 Electro-hydraulic diagram motor pump for slewing and lifting cylinder 1 Motor pump 2 Valve bank 3 Lifting cylinder 4 Overcenter valve 5 Hydraulic motor 6 Oil tank 7 Filter 8 Unipolar battery disconnector 9 Button 10 Relay Calibration overpr. valve 170bar Pict. -
Page 43: Electrical Winch Wiring Diagram
10.8 Electrical winch wiring diagram Raising button Lowering button Remote control reverser Winch electric motor Unipolar battery disconnector Pict. 39 Via Mediterraneo, 6 - 42022 - Boretto - Reggio Emilia - Italy - 39 - Tel. +39 - 0522-96 30 08 - Fax +39 - 0522-96 30 39 info@maxiliftcrane.com... - Page 45 © COPYRIGHT BY NEXT HYDRAULICS S.r.l. © Ideazione e realizzazione by "Studio Pinotti" R.E. © Layout and publication by "Studio Pinotti " R.E. Riproduzione e divulgazione vietati a termine di legge senza autorizzazione scritta della Next Hydraulics S.r.l. Reproduction and distribution are forbidden according to law without written permission in writing from Next Hydraulics S.r.l.
- Page 46 NEXT HYDRA NEXT HYDRA ULICS S NEXT HYDRA ULICS S ULICS S ULICS S .r .r .r .r .r .l. .l. .l. .l. .l. NEXT HYDRA NEXT HYDRA ULICS S Via Mediterraneo, 6 Boretto (RE) -ITALY Tel.0522/963008 - Fax 0522/963039 info@maxiliftcrane.com...
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