Installation manual for HESTAL 855 Liftmaster
Contents
1. washer B 10 DIN 125 hex nut M10 DIN 982 g T 8 PL union tee Handipum Lead through to quick plug in pump connexion for air hose 8 NW 6 Connexion for pipe 8 main line 2 General information On left and right sides The HESTAL 855 Liftmaster is designed for raising a roof up to 580mm One lifting mechanism width 60mm amp depth 30mm is welded into each of the corner frame profiles of the vehicle superstructure The working unit is fitted at a suitable point underneath the vehicle frame Any modifications to the HESTAL 855 Liftmaster or failure to adhere to the installation manual render all liability claims null and void 3 Regulations In addition to this installation manual the following regulations and guidelines must be observed BG Employer s Insurance General Regulations BGV A1 BG Winching Lifting and Traction Equipment regulations BGV D8 BG Vehicles regulations BGV D29 VDI Association of German Engineers Guideline 2700 Securing Loads on Road Vehicles Vehicle manufacturer s construction guidelines StVZO Road Traffic Licensing Regulations Hydraulic oils DIN 51524 Pipe connexions DIN 2353 Seamless precision steel pipes DIN 2391 Pipe fitting manufacturer s general instructions and assembly instructions Hoses reinforced with wire mesh DIN 20022 Requirements for fitting hoses DIN 20066 Hose fittings DIN 20078 9 Safety regulations for hydraulic hoses ZH 1 74 Dated 10 20052. 10 2005 Technical modifications reserved page 3of 7 F Hesterberg amp S hne GmbH amp Co Kg Heilenbecker Str 50 60 D HES TERBERG 58256 Ennepetal Phone 49 0 2333 794 0 e mail info hestal de Fax 49 0 2333 794 115 http www hestal de Installation manual 6 810 064 49 7 Performance test Performance test on control unit and pump unit on baseplate see also Operating Instructions Preselect roof side Switching the ball valve for the right or left side of the roof determines which side is to be raised Attention The centre supports must be fitted with telescopes and be located in the fastening points located on the vehicle frame Raise roof The pump is switched on by opening the air shut off valve switch is parallel to pipe The vehicle roof is now raised This procedure may be interrupted at any point you choose by switching the pump off again When both roof sides have to be raised the ball valve of the raised roof side must be closed before On completion of the raising procedure the pump must be switched off by means of the air shut off valve Lower roof The vehicle roof is lowered by opening the handwheel This procedure may be interrupted at any point you choose by closing the handwheel Only the side with opened pipe can be lowered select ball valve When the lowering process is complete the handwheel must be closed again Performance test on hand pump see also Operating Instructions Attent
3. 400 QB11 6 810 064 30 114 10006 2 Pressure cylinder ED16 1000 QB11 6 810 064 35 1114 40024 Dated 10 2005 Technical modifications reserved page 5of 7 F Hesterberg amp S hne GmbH amp Co Kg Heilenbecker Str 50 60 58256 Ennepetal Phone 49 0 2333 794 0 Fax 49 0 2333 794 115 10 Drive units a Pump unit on baseplate b Control unit c Hand pump Connection for pipe 8L 375 43 Dated 10 2005 1 Po Ae e mail info hestal de http www hestal de D HESTERBERG Installation manual 6 810 064 49 570 i 28 30 ar Hk I a mero 1 RECHTE SEITE r 4 RIGHT SIDE r ipo t 4 H gt D i Connexions for i ns Hydraulic cylinder pipe 8L zE Connexions for Xe gt PE Hydraulic cylinder 8 8 UNESETE pipe 8l amp LEFT SIDE fq air connexion A for hose 8 18 y i EMERGENCY HAND PUMP 6 8 ml double stroke lrs ia amp Le 600 Connexions for Hydraulic cylinder pipe 8L 2 way ball valve ON 4 x im 210 X View X ry r N Roof right fo SX Sy a S B M Roof left fe hag Y l IN es a T 4 air connexion for hose 8 N Installation position as shown N Or turned through 90 y o y 3 1 3 630 Pump lever Handwheel
4. 912 or 6912 bolt length to be chosen by the vehicle manufacturer B8 washers in accordance with DIN 125 and self locking M8 hex nuts in accordance with DIN 982 or 985 parts not supplied In addition the bolted joints must be painted with a suitable thread locking substance The thread locking substance suitable for the expected stress must be chosen by the superstructure manufacturer Pneumatic connexion 10 bar maximum permitted operating pressure a cabins b articulated lorry trailers and vehicles with pneumatic shock absorption a If not already present an auxiliary user connexion point must be installed to serve as a four circuit safety valve The HESTAL 855 Liftmaster is connected here to Connexion Point 23 as an auxiliary user unit b An over current or reverse current valve must be fitted to the pressure tank for brake system or air shock absorption to which the HESTAL 855 Liftmaster is connected For this you can use a pressurised air hose of the type generally used in vehicle construction and preferably of polyurethane with an external diameter of 8mm NW 6 The air pressure hose is led into the steel housing through the hole provided and pushed as far as it will go into the air shut off valve quick plug in connexion Attention the end of the hose must be cut at a right angle The hydraulic cylinders must be provided with the GE 8 PLM screw in connexion and each must then be mounted in the U profile of the lifting mecha
5. enclosed S INS Q BA S En a tr a 200 al page 6of 7 F Hesterberg amp S hne GmbH amp Co Kg Heilenbecker Str 50 60 D HES TERBERG 58256 Ennepetal Phone 49 0 2333 794 0 e mail info hestal de Fax 49 0 2333 794 115 http www hestal de Installation manual 6 810 064 49 11 Note for setting up with only two lifting mechanisms If it is intended to raise the vehicle roof on one side only the vehicle manufacturer must provide suitable roof hinge bearings on the side of the vehicle not to be raised See Fig 7 Also the unused main line out on the control unit must be filled with a blind plug see circuit diagram Fig 4 For practical reasons the control unit must be attached to the side of the vehicle to be raised Figure 7 Hinge point Example of assembled control unit Dated 10 2005 Technical modifications reserved page 7of 7
6. F Hesterberg amp S hne GmbH amp Co Kg Heilenbecker Str 50 60 D HES TERBERG 58256 Ennepetal Phone 49 0 2333 794 0 e mail info hestal de Fax 49 0 2333 794 115 http www hestal de Installation manual 6 810 064 49 Installation manual for HESTAL 855 Liftmaster For use by vehicle construction plants and trained specialised staff Installation work NOT to be performed by inexperienced personnel If you have any problems or queries regarding installation we would be glad to provide you with further assistance over the telephone KS Assembly hinge bearing Table of Contents Page System overvieW esesssssserssesrerererrererersrnererens General information Regulations ccccccceececceeeeeeeeeeeneeeeeaeeeeeeaeeeeeeaeeesenes General principles 0 ccceeeeeeeeeeee sees ee eeeeaees Installing the HESTAL Liftmaster 5 1 Installing of lifting mechanism 5 2 Installing of control unit hydraulic cylinder pipe layout aRWN gt Assembly lifting mechanism Pg Important information Circuit diagram and parts list Drive UNS sidii naris severe tie svaseiesetouedecenediecusecid sock Note for setting up with only two lifting mechanisms 3 OOND NOOB BRWWWNDND A A o ko 1 System overview Hydraulic cylinder DIN EN 28752 Screw in connexion Spring pin GE 8 PLM 10x50 S amp Controlunit ne FS Cylinder bolt M 10x80 DIN 912
7. Technical modifications reserved page 1of 7 F Hesterberg amp S hne GmbH amp Co Kg Heilenbecker Str 50 60 D HES TERBERG 58256 Ennepetal Phone 49 0 2333 794 0 e mail info hestal de Fax 49 0 2333 794 115 http www hestal de Installation manual 6 810 064 49 4 General principles The HESTAL 855 Liftmaster is designed for a total maximum roof weight of 1 000kg Additional loads such as snow ice etc must be removed prior to operation in case they slide off Maximum lifting force 2 000kg The lowered roof must be positively locked using appropriate technical measures e g lugs The superstructure manufacturer has integrated the HESTAL 855 Liftmaster s lifting mechanism in the corner supports The lifting mechanism and its profile must not be included when strength is evaluated The centre supports must be fitted with telescopes allowing the roof to be raised by 580mm e g HESTAL 700 7 centre support with 600 telescope On no account must the ultrahigh pressure hydraulic hoses also be painted In addition all connexions must be secured with a suitable thread locking substance to be chosen by the superstructure manufacturer Only genuine HESTAL parts must be used for maintaining or repairing the HESTAL 855 Liftmaster ZN Driving with the roof raised even only slightly is not permitted 5 Installing the HESTAL 855 Liftmaster 5 1 Mounting the lifting mechanism The lifting mechanism can be welded into t
8. WS standard The hinge bearing should be welded under the roof connecting plate as shown in Figure 2 and positioned so that there is some play between moulded hinge bearing and outside of the vehicle taking the length of the side of the vehicle into account In this way Figure 2 shows the mounting of the left front or right corner pillar The roof connecting plate sits on the corner pillar and must be chosen by the superstructure manufacturer depending on the roof design Dated 10 2005 Technical modifications reserved page 2of 7 F Hesterberg amp S hne GmbH amp Co Kg Heilenbecker Str 50 60 D HES TERBERG 58256 Ennepetal Phone 49 0 2333 794 0 e mail info hestal de Fax 49 0 2333 794 115 http www hestal de Installation manual 6 810 064 49 5 2 Fitting the drive unit and the hydraulic cylinders and line installation The line installation for the HESTAL 855 Liftmaster and the assembly of the working unit and the hydraulic cylinders must be completed by the vehicle manufacturer with those tasks being carried out by personnel suitably specialised in hydraulics The drive unit with baseplate mounted control unit and pump unit or alternatively hand pump is fitted with as much protection as possible in a suitable place and in a stipulated installation area under the vehicle frame For this purpose you should use four bolts with M8 thread in accordance with DIN 931 933
9. he corner frame profiles of the vehicle superstructure either on the left on the right or in the centre Figure 1 All welded seams a 4 GY A 4 4 y af T 7 A A K 7 Z A f A f j ZA OITIIIIIIIIZIIIIZZA Lib plitigigiiflilhee CLL ALLL ELLA hhh LLL EL g Lk Corner pillar profile chosen by superstructure manufacturer After the lifting mechanism has been aligned the following seams must be welded On both sides beginning at the upper end of the U profile each 50mm in length with a weld seam thickness of a 4mm Underneath that 10 welded seams each 40mm in length with 150mm between them and a weld seam thickness of a 4mm U profile length 1950mm Distance from the upper end to the lower edge of the roof connecting plate 50mm Figure 2 Fitting the hinge bearing to the roof connecting plate In order to prevent crevice corrosion cover any unwelded parts with sealant Weld executed according to DIN EN ISO 13920 BF DIN EN 25817 C DIN EN ISO 9692 2 and DIN EN 29692 The choice of materials and dimensions for the corner supports as well as the choice of a suitable welding material must be determined by the superstructure manufacturer with regard to the loads permitted and expected in this case Example If the corner support is made of Item 52 3 we recommend a NiFe wire for welding and as a welding electrode ENIFEBG11 in accordance with DIN 8573 or ENIFE C in accordance with the A
10. hicles accident prevention regulations BGV D29 The Operating Instructions provided must be attached to the vehicle documents and kept in the vehicle itself Dated 10 2005 Technical modifications reserved page 4of 7 F Hesterberg amp S hne GmbH amp Co Kg Heilenbecker Str 50 60 58256 Ennepetal Phone 49 0 2333 794 0 Fax 49 0 2333 794 115 e mail info hestal de http www hestal de 9 Circuit diagram and parts list Figure 4 Figure 5 Parts list Circuit diagram D HESTERBERG Vehicle side left Installation manual 6 810 064 49 right O y d u Pipe Layout R 8x1 11 1 Parts list Item Designation dimensions Hestal No ID No 1 Control unit 6 810 064 10 299 40339 Pump unit on baseplate 6 810 064 25 299 40340 consisting of 11 Compressed air hydraulic pump 6 810 064 09 252 40004 anually operated pressure valve Drain valve and 1 litre tank odel LPH 100 12 6 250 1 12 Oscillating valve Model 900 52 5N 51 8 6 810 008 21 9304 10020 13 Sound absorbers 6 810 008 07 884 10044 14 3 2 way stop valve Model HE 3 QS 8 6 810 064 06 904 1001 15 2 2 way ball valve ON 4 PN 500 St M 16x15 6 810 064 05 9309 10082 possible cylinder models 2 Pressure cylinder E016 580 QB11 6 810 064 20 114 10032 2 Pressure cylinder E016
11. ion The centre supports must be fitted with telescopes and be located in the fastening points located on the A vehicle frame Raise roof Insert pump lever in hand pump mount and start pumping process The vehicle roof is now raised This procedure may be interrupted at any point you choose Lower roof The vehicle roof is lowered by opening the handwheel This procedure may be interrupted at any point you choose by closing the handwheel When the lowering process is complete the handwheel must be closed again A Then the system must be checked once more for a tight seal 8 Important Information Adhering to the installation and operating manuals will ensure the HESTAL 855 Liftmaster functions perfectly During the lowering operation there must be no one in the loading area or on the load itself It is permitted to operate the HESTAL 855 Liftmaster only with extendible centre supports e g HESTAL 700 7 centre support with 600 telescope The lowered roof must be positively locked using appropriate technical measures e g lugs Driving with the roof raised even only slightly is not permitted For reasons of operational road and work safety only combinations of the HESTAL parts illustrated here are permitted When properly installed the Liftmaster conforms to the stipulations of Appendix 1 Basic Safety and Health Requirements in the Design and Construction of Machines of the EU Machine Guideline 89 392 EEC and the Ve
12. nism with an M10x80 DIN 912 cylinder bolt 8 8 strength category a B10 DIN 125 washer and a M10 DIN 982 hex nut 49Nm tightening torque in addition each piston rod is connected to the thrust plates by a spring pin mounting holes may have to be made in the corner supports The cylinder stroke should be in an upward direction and the cylinders must be fitted so that the bleeder screw is accessible In addition the bolted joints must be painted with a suitable thread locking substance The thread locking substance suitable for the expected stress must be chosen by the superstructure manufacturer Connecting the hydraulic line to the control unit and the pump unit on baseplate Lay both main connecting lines on the left and right sides of the drive unit as far as the centre of the vehicle and from there connect the T 8 PL union tee to the hydraulic cylinders on the appropriate side In the vehicle frame 8x1 35 4 NBK DIN 1630 2391 lines made of galvanised steel pipe are used for this purpose Connecting the hydraulic line to the hand pump a hand pump is needed for each side of the vehicle Lay the connecting main line as far as the centre of the vehicle and from there connect the T 8 PL union tee to the hydraulic cylinders on the appropriate side In the vehicle frame 8x1 35 4 NBK DIN 1630 2391 lines made of galvanised steel pipe are used for this purpose A flexible ultrahigh pressure hydraulic hose in accordance with DIN 20022 250 bar nominal
13. pressure with 8 L hose connexion connects the main steel pipe line to the hydraulic cylinders in the corner supports Care must be taken to ensure that the steel pipe line is laid and fastened inside the vehicle frame in such a way that it cannot rub against edges or lead throughs or become damaged in any other way The pneumatic and hydraulic lines should be concealed when they are laid inside the corner supports and the vehicle frame Pipes must be adjusted stress free before assembly Pipe systems must be fastened with suitable pipe clamps at specific intervals With 8 mm pipe the distance between the clamps must be 900mm Hydraulic hoses which are laid in the actual working area and are exposed to traffic must be shrouded A If there are no manufacturer s stipulations the hydraulic hoses must be replaced because of age after a maximum period of six years 6 Start up Fill oil tank up to the mark with HLP 10 hydraulic oil which complies with DIN 51524 Open the bleeder screws on the hydraulic cylinders Allen key SW 4 If necessary bleed pipes in advance Start pumping process pneumatically or manually see Operating Instructions Depending on the length of the pipes it may be necessary to fill the oil tank again up to four times until the pipes and the hydraulic cylinders are completely full After the system has been bled completely fully tighten all pipe connexions and the hydraulic cylinder bleeder screws again Dated
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