Sörensen Hydraulik GmbH Osterrade 3 - D-21031 Hamburg phone: fax: internet: e-mail: +49 (0) 40 / 739 606 0 +49 (0) 40 / 739 606 66 www.soerensen.de info@soerensen.de Sales department: phone: +49 (0) 40 / 739 606 14 fax: +49 (0) 40 / 739 606 69 e-mail: info@soerensen.de Spare parts: phone: fax: +49 (0) 40 / 739 606 68 +49 (0) 40 / 739 606 77 Sörensen Hydraulik GmbH - Osterrade 3-21031 Hamburg - Tel +49 (0)40 739 606 0 - www.soerensen.de Sörensen Hydraulik GmbH
Assembly instructions X1 500SL / X1 750SL Preparation of the vehicle Take off the tail lights and the original underrun bar if necessary. You will find all measurements for the assembly on the tail lift master sheet page 21 for groups 1 and 2, and on page 22 for group 3. If there are any brackets, rivets screws or couplings in the assembly area of the tail lift brackets or the adapters, they must be removed. If necessary, remove hinges and locks from the vehicle s body. The drivers cabin should be protected against dirt using a suitable cover. Caution! The body seal has to be mounted before the tail lift See page 20 or 21. Install the sub frame according to instructions and manuals of the chassis manufacturer Attention! If changes to the vehicle s frame must be performed, it is essential to conform with the directives of the frame s manufacturer. For tasks which are not described in the assembly guidelines, a written agreement of the vehicle s manufacturer must be obtained. Cutouts in the rear frame Measurements for cutouts in the rear beam of the body Middle-middle lifting and tilting arms More measures (side and overwiev) can be found on pages 20 and 21 of the master sheet. Mechanical support stands The directives of the vehicle manufacturer state if the vehicle should be equipped with support stands. Please only use support stands delivered with the tail lift. Assembly instructions Nr.:20 908 285 / 288 and 291 Type X1A 500SL / X1A 750SL Preparation of the vehicle 2 Version 15.02.2008
Assembly preparation / Use of the drilling gauge Attention! Prior to the assembly, it must be verified thouroughly if the vehicle and its technical data corresponds to the vehicle group or subgroup of these assembly instructions. In order to provide a simple and easy assembly without using disproportional means, we must offer various armlength, assembly brackets and assembly adapters for the different vehicle types. We have classified those into the following groups. Group 1 Frame widths R965 / R995 / R1110 / Assembly instructions Nr. 20 908 285 A Mercedes Sprinter BM 906 - VW Crafter B Ford Transit C Renault Master - Opel Movano - Nissan Interstar Group 2 Frame widths R1315 / Assembly instructions Nr. 20 908 288 Fiat Ducato - Peugeot Boxer - Citroen Jumper Group 3 Frame width R 700 through 860 / Assembly instructions Nr. 20 908 291 Vehicles with U profile frames The assembly descriptions are divided in sections according to the frame width and vehicle groups. Before assembling the lifting gear, it must be ensured that the screw (A) (connection between tilting arm/underride bumper) is not tight. It will be tightened only after adjusting the lifting gear (see page 16) Underride bumper Adjusting fork Tilting arm A Please verify if Sörensen Hydraulik GmbH delivered a special drawing for the assembly of this tail lift. If so, the assembly must be performed according to that particular drawing. Please check with your services (purchasing or order follow-up). Assembly instructions Nr.:20 908 285 / 288 and 291 Type X1500SL / 750SL Assembly preparation 3
Using the drilling gauge for lifting gear assembly For the assembly of the tail lifts for all vehicle groups, we use drilling gauges (accessory code: 551), delivered when desired with the tail lift. Those gauges are composed of three parts, gauge 1 lays on the body floor, gauge 2 is a copy of the lifting arm and gauge 3 is a copy of the bracket used to tighten the tail lift to the vehicle s chassis. According to the amount of vehicle types and chassis, we need different armlength and assembly brackets. Therefore, the gauges 2 and 3 exist in various models, matching the different vehicles and their chassis, and who are classified into the same groups than the vehicles. The right gauges are delivered with the tail lift. Please proceed as follows: Lay gauge 1 on the body floor and secure it with a screw clamp. Hang in gauges 2 and 3, align gauge 3 parallel to the vehicle chassis and transfer the 5mm holes of the gauges onto the vehicle s chassis, on both sides. Please provide enough space If a body seal is mounted. Thickness of body seal profile Sörensen 40mm Assembly instructions Nr.:20 908 285 / 288 and 291 Type X1500SL / 750SL Assembly preparation 4
Assembly of the lifting gear on vehicles of group 1 A+B with framewidth R965 / R995 The lifting gear is delivered on a pallett, ready for assembly. For assembling the tail lift, the holes necessary to tighten it on the vehicle s frame must be transferred from the drilling gauge on to the sub frame and drilled through. Attention! Gauge must be parallel to the vehicle frame. See page 4. The right drilling gauge is delivered with the first lift and remains at the bodybuilder for further assemblies. Since two armlengths (515mm and 575mm) are possible, it must be verified that the correct part of the drilling gauge is used. The gauge is an exact copy of the lifting arm and the assembly brackets, so it s easy to check if the parts of the tail lift correspond to the gauge. You will find drawings containing the measurements for the hole distances of the assembly brackets on page 8. After drilling the holes into the subframe, the lifting gear is taken under the vehicle on its pallett, adjusted according to the holes and fastly tightened to the sub frame. On the master sheet page 21 (data sheet for assembly) you will find all possible assembly min. and max. measurements. Assembly bracket Assembly fixture Bolt the assembly brackets left and right to the vehicle frame. Please use the holes already drilled for the original underride bumper. Finally, assemble and tighten the supporting rods and adjusting forks on both sides between the assembly bracket and the assembly fixture (also see page 7). Supporting rod This assembly fixture is used for Mercedes Sprinter, VW Crafter and Ford Transit. If there is not enough space available, a verification of the assembly situation through our services (sales department) is necessary. If we determine that the assembly is possible under the given circumstances, we will send you a separate and specific drawing, explaining how to assemble the tail lift. Assembly instructions Nr.:20 908 285 Type X1500SL / 750SL Group 1 Assembly lifting gear 5
Assembly of the lifting gear on vehicles of group 1C with framewidth R1110 The lifting gear is delivered on a pallett, ready for assembly. The assembly is identical to groups 1A+B, except for the assembly fixture. Bolt the assembly fixture left and right on to the vehicle frame, please use 2 holes under the vehicle chassis, as well as one matching side hole. This assembly fixture is used for Renault Master, Opel Movano and Nissan Interstar. Socket Finally, assemble and tighten the supporting rods and adjusting forks on both sides between the assembly bracket and the assembly fixture (also see page 7). If there is not enough space available, a verification of the assembly situation through our services (sales department) is necessary. If we determine that the assembly is possible under the given circumstances, we will send you a separate and specific drawing, explaining how to assemble the tail lift. Assembly instructions Nr.:20 908 285 Type X1500SL / 750SL Group 1 Assembly lifting gear 6
Assembly of supporting rods and adjusting forks When the brackets and fixtures are fastly tightened with the vehicle frame and the subframe, we assemble one supporting rod and one adjusting fork on each side, between the assembly bracket and the assembly fixture. The adjusting forks are used to prespan the supporting rod Example group 2 Assembly fixture Assembly bracket Supporting rod Adjusting fork Assembly instructions Nr.:20 908 285 Type X1500SL / 750SL Group 1 Assembly lifting gear 7
Drilling distances for assembly bracket Group 1 Long Short Caution! When drilling holes into the vehicle frame, the directives of the vehicle s manufacturer must be observed. The nuts necessary to fasten the tail lift are to be taken from the side package of the lift. Group 1 Verbus Ripp M16 x 10.9 Assembly instructions Nr.:20 908 285 Type X1 500SL / 750SL Group 1 Assembly bracket 8
Assembly of electrical equipment Caution! The features of the tail lift can only be operated, even temporarily, if the battery cables are connected firmly to it and if there is enough voltage available. Never use a loading or starting device, as this will heavily damage the electric motor and the power relay.. The operation of the Service Switch is extensively described page 20 Plug connection power unit Plug connection platform Cable to cabin switch Cable to cabin switch Kabel zum Einschalter im Fahrerhaus If possible, the cabin switch is to be mounted according to the provided wiring diagram in a free original space on the dashboard. If that is not possible, a free space has to be found, in which a 16mm hole can be drilled for the switch assembly, without damaging any parts or cables behind it. Then, lead the cable from the cabin switch to the tail lift and connect it to the round plug on the control box. Assembly of the control box The control box must be assembled on the right side of the vehicle, so that the operator can oversee the whole platform while operating the lift. The distance between the rear edge Of the body and the middle of the control box must be 400 mm ± 100 mm European Norm EN 1756-1 The control box is attached with two screws M8, 8.8, passed through the 8.5 mm holes and fastened with two self-retaining nuts or secured with loctite. 400 mm +/- 100 mm Sörensen Assembly instructions Nr.: 20 908 285 / 288 and 291 Type X1 500SL / 750SL Assembly of electrical equipment 9
Leading the cable to the foot control Lay the cable (platform connection) with the red-yellow-black plug from the control box along the lifting arm to the platform. Attach the footcontrol cable on the loops with the provided cable straps Connect both halfs of the plugs and push the whole unit into the platform cavity Capacity Fuse Battery 12 Volt 1 x 88 Ah 150A 150 A Fuse Assembly instructions Nr.: 20 908 85 / 288 and 291 Type X1 500SL / 750SL Assembly of electrical equipment 10
Warning Sticker secure the load This sticker is not provided by Sörensen Hydraulik GmbH. You can order the sticker at our factory under item Nr. 20 904 940. This sticker is a warning information stating that there are situations during loading and unloading trucks with a tail lift in which the front axle might lift. On the consequent slope, unsecure load can come to motion and constitute a danger to persons. Tag the sticker secure the load on the free surface above the operating sticker on the control box. If this surface can not be seen by the operator, please stick it on a well seen surface above the control box on the truck body. Caution! Secure the load on the cargo area against slipping or use stands. Sörensen Hydraulik GmbH 20 904 940 Warning! Do not exceed the maximum load of 750 kg in order to avoid heavy damage to the vehicle. max. Load distance 600mm Vehicle The maximum load shall be placed on the platform center and shall not exceed the maximum load distance of 600 mm See also the type tag on the lifting arm and in the power unit hood. Assembly instructions Nr.: 20 908 285 / 288 and 291 Type X1 500SL / 750SL Assembly of electrical equipment 11
Assembling and adjusting the platform. Type A B X1A 500SL X1A 750SL 180 58 + Body seal? Platform Assembly The lifting unit is lowered enough to allow an easy assembly of the platform. Apply some of the special grease provided on the platform and tilting cylinder bearings put on the O-ring gaskets hang in the lifting arms and the tilting cyclinder, mount the bolts and secure them. Adjusting the platform to the vehicle floor With the control box, place the lifting unit near the rear vehicle frame. The lifting arms shall not touch the rear beam, please leave a gap of about 10 mm.with the adjusting screw, the lifting unit is adjusted so that the rear frame and the platform are parallel with each other. After adjusting the platform, both security screws (A) of the underride bumper must be tightened. Assembly instructions Nr.:20 908 285 / 288 and 291 Type X1A 500SL / X1A 750SL Platform assembly 12
Function of the adjusting fork After the assembly, both lifting arms shall touch the rear beam at the same time, and must not spring when the platform is loaded A If necessary, this adjustment is made with the adjusting fork located on the right lifting arm. If the screw is turned to the right, the lifting arm is tightened more against the rear beam. If the screw is turned to the right, the lifting arm is tightened more against the rear beam. If the adjusting screw is turned to the left, the lifting arm lowers away from the rear beam. Assembly instructions Nr.:20 908 285 / 288 and 291 Type X1A 500SL / X1A 750SL Platform assembly 13
Lifting arm stop at vehicle body If you assembled the tail lift correctly, both lifting arms will stop at the same time on the rear vehicle frame. If this should not be possible due to the assembly configuration, it is essential that the lifting arm stops only with the head of the spring against the rear beam and that the side plates can be pushed freely against the lifting arm head. Eventually reinforce the rear beam in the area where the lifting arms push against it, so that it is not crushed when lifting with hydraulic pressure. Always push the lifting arms against a plain surface. Fill any edge so that the heads always push against a plain and firm surface. The body could be lifted and the spring of the lifting arm not work properly. Adjusting the closed platform against the body Close the platform with the control box. The cylinder must come to its internal limit when the platform is leaned lightly against the rear frame, or when the platform forms a 90 angle with the vehicle floor. If the platform pushes with full pressure against the rear frame without reaching the cylider s limitation, the length of the piston rod has to be adjusted. Open the platform 10 to 15, in order to relieve the cylinder. Untie the counternut on the piston and turn the piston head one way or the other to shorten or lengthen it. Try out the settings, by closing the platform again, in order to perform a preliminary tension. Only then, retighten the counternut. Assembly instructions Nr.:20 908 285 / 288 and 291 Type X1A 500SL / X1A 750SL Platform assembly 14
Adjusting the platform tilting Turning the adjusting screw to the right the upward tilting shuts down earlier. The platform tip shows further down. Turning the adjusting screw to the left the upward tilting shuts down later. The platform tip shows further up. Assembly instructions Nr. 20 908 285 / 288 and 291 Type X1A 500SL / X1A 750SL Section adjusting the platform 15
First operation of the tail lift Verify the tail lift readiness for operation. Check that all moving parts can move freely (no pinching or rubbing of cables or lines etc ) Check the hydraulic system for leakage. Hydrauliköl Empfehlungen Suggestions for hydraulic oil HLPD 22 (ISO-VG 22) "detergent", to emulsify free water (to avoid ice formation in winter operation) and to improve the oil film cohesion. Sörensen Hydraulic oil Part Nr.60 700 283 Sörensen Hydraulic oil HLPD 10 Part. Nr. 20 841 181 Sörensen Bio-Oil Part Nr. 20 858 811 Aral Vitam DE 22 Shell Hydrol DO 2 BP Energol H LPD 22 Panolin HLP SYNTH (Bio-Oil) BP Biohyd 32 (Bio-Oil) DEA Actis HLPD22 DEA Econa E 22 (Bio-Oil) Mobil Oil H-LPD 22 Esso Hydraulic Oil H-LPD 22 Fuchs Rhenolin MR 5 Painting the lifting unit The lifting unit is delivered powder or KTL-coated from the factory. If another painting should be wished for, it has to be performed by the bodybuilder (please remember to sand the lifting unit before any paint job). It is also essential to very carefully protect the black piston rods, ideally with tape. Remove all tape and paint rests from the rod prior to tail lift operation as these can damage the seals and will cancel the warranty. Operation instructions The sticker showing the instructions for operating the tail lift is tagged on the control box by the factory. Type label The type label, containing the loading diagram is tagged on the right lifting arm (in driving direction), a second label is tagged by the factory into the power unit hood. Entry into the test book After completion of the assembly, the paragraph of the test book Test before first operation has to be filled out and signed by qualified personnel Checking the operation speeds Vertical speed The vertical speed (lifting and lowering) must not exceed 15cm/sec. If lifting and lowering are too fast, please check the voltage on the vehicle and on the power unit. The two values must be identical. Should lowering and opening be too fast, please verify if the throttles work properly or if they are dirty. In both cases, please call the Sörensen Hydraulik GmbH service department! Opening and closing speed If the platform is not closed and/or opened by hand, the angle speed must not exceed 10 /sec. Tilting speed The angle speed for tilting shall not exceed 4 /sec. The platform tilting must be limited to a maximum of 10 Assembly instructions Nr.:20 908 285 / 288 and 291 Type X1A 500SL / X1A 750SL First operation 16
Load probation Static test Place the platform half way between the ground and the vehicle floor. Place a weight up to 125% of the nominal capacity in the middle of the platform within the loading distance. The permitted loading distance and the nominal capacity are engraved on the type label of the tail lift. The load diagramm shows the capacity modifications according to the distance from the vehicle. Within a test time of 15 min, the lift must not lower more than 15 mm nor tilt down more than 2. The bodybuilder is bound to check the tail lift for deformations after the static test. Dynamic test The functions lifting, lowering and tilting are to be checked with a load complying with the loading diagram. If necessary, adjust the hydraulic pressure valve so that the given load can be lifted securely. Caution! The pressure valve is factory set, normally a correction is not necessary. If that correction should be necessary anyway, please comply with following instructions: Perform a setting of the pressure valve only by connecting a pressure gauge with which the pressure can be veryfied. The maximum allowed pressure is engraved on the type label. After the static and dynamic tests, a visual leakage inspection of the hydraulic system must be performed. Test against lifting an overload With a test it must be ensured that the device will not lift a load greater than 125% of the nominal capacity from the ground. Verification of security features All functions of the tail lift have to be operated until the security features are activated. Warning flags Attach the warning flags according to the assembly instructions provided.. B A Measurement A 20mm gap between platform and road when platform is open Measurement B Place warning flag as far as possible to the platform edge left and right Assembly instructions Nr.:20 908 285 / 288 and 291 Type X1A 500SL / X1A 750SL First operation 17
Valid torque chart for all delivered and assembled screws on Sörensen tail lifts. Screw dimensions Torque in Nm Couplings Torque in Nm DIN 3852 8.8 M4 2.7 G1/4 40 M6 9.5 G3/8 95 M8 23 G1/2 130 M10 46 Union Nut M12 80 12L M14 130 16L 60 M16 195 18L 60 M20 385 Plugs G1/8 15 10.9 G1/4 33 M10 70 G3/8 70 M12 115 M14 180 M16 275 M20 542 Flangescrew Mercedes Norm 10.9 M14 MBN 10105 215 M16 MBN 10105 310 Locking Screws Sleevenuts Flangescrew Mercedes Norm 10.9 M14 MBN 13023 215 M16 MBN 13023 310 Assembly instructions no.: 20 908 285 / 288 and 291 Type X1A 500SL / X1A 750SL First operation 18 Modification: 01.09.2015
Service Switch Over the switching unit mounted in the power unit (Service Switch), authorized personnel can operate and test directly all the tail lift functions. In case of a failure of the control box or the footswitch, a trained person can drive the tail lift to any of its positions with that Service Switch (emergency function). Option Internal body light The plug strip offers the possibility to connect the internal light of the body. The light is switched on and off at the same time as the tail lift, with the cabin switch and is protected by a 5 ampere fuse. Y3 YA Internal body light KM Y1 Mounted blinking relay, only on internal body light version Fuse for body light Function YA Y1 Y3 KM Lifting Lowering Opening / Tilting low Closing / Tilting high Please respect sequence, switch KM always last Assembly instructions Nr.:20 908 285 / 288 and 291 Type X1A 500SL / X1A 750SL Service Switch 19
Body Seal 1 Rubber profile 20 840 321 3,0 mtrs 2 Rail (aluminium) 20 840 542 2,6 mtrs 3 Rubber profile 20 904 899 2,5 mtrs 4 Aluminium profile 20 905 044 2,5 mtrs 5 Stopper 150mm wide 20 905 047 2 pieces 6 Allen screw 20 905 217 4 pieces 7 Hex screw 20 905 218 6 pieces Stopper distance middle to middle lifting arm. By tilting (180 ) they can be used on any standard tail lift Montageanleitung Nr.:20 908 285 / 288 und 291 Baureihe X1A 500SL / X1A 750SL Dichtprofil Koffer 20