/1500 Verlichting, signalisatie, bumpers en elektriciteit | Catalogus Morado editie 2025 Morado is uw gespecialiseerd leverancier van carrosserieonderdelen en -uitrusting voor lichte en zware bedrijfsvoertuigen | Oudsbergen, BELGIË
INSTALLATION MANUAL HYDRAMAX LIFTING SYSTEM
General
3
Specifications
4
2.1 2.2
Hydramax pump units Hydramax Cylinders
4 6
Installation
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3.1 3.2 3.3 3.4
Installation Axces Connect Installation Cylinder 500/1000 Installation Hydramax pump unit Connecting and filling the system
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11 17 18
Axces Connect Lift & Drive
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2
GENERAL
The Hydramax lifting system ensures a smooth and synchronous lifting of the trailer roof, since all of the connected cylinders will rise simultaneously. This makes the system very suitable for lifting roofs with a very stiff structure which are vulnerable to twisting and wringing.
Important notes
The only way to lift both sides of the roof separately using Hydramax, is to use two complete Hydramax 2 systems, one for the left side and one for the right side. In this case, the maximum lifting height is always 500 mm; the 1000 mm lifting height option is not available in this configuration because this will put too much stress on the mechanical parts when lifting only one side of the roof. The maximum input air pressure for the Hydramax 4 and 6 is 10 bar , the maximum pressure for the Hydramax 2 is 6 bar . This means that it’s not always possible to connect the pump directly to the air supply of a truck or trailer, please check this before installation.
In case of Hydramax 2, the use of a regulator to reduce the pressure to 5 - 6 bar is always necessary!
Available versions
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SPECIFICATIONS
2.1
Hydramax pump units
Hydramax 2 802-01014
912
1281,5
Hydramax 4 802-01012
Hydramax 4 802-01015
Hydramax 6 802-01013
Hydramax 6 802-01016
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General specifications Hydramax pump-units
Operating input air-pressure:
Ì
Hydramax 2:
5 - 6 bar, max 6 bar 6 - 8 bar, max 10 bar
Hydramax 4 and 6:
Maximum hydraulic output pressure:
Ì
Hydramax 2 (at 6 bar input air pressure): Hydramax 4 (at 10 bar input air pressure): Hydramax 6 (at 10 bar input air pressure):
237 bar 198 bar 132 bar
Lifting capacity:
Ì
Hydramax 2 (at 6 bar air pressure): Hydramax 4 (at 8 bar air pressure): Hydramax 6 (at 8 bar air pressure):
1500 kg (2 Hydramax 2 units)
1200 Kg Max 1200 Kg Max
Male G1/4
Hydraulic connections for Cylinders:
Ì Ì Ì Ì
Ø8 mm
Air hose connections:
HLP 46 or 68
Recommended hydraulic oil:
3 L
Capacity oil tank:
Recommended hydraulic hoses:
Ì
Hydramax 2: Hydraulic hose with 1 steel webbing (Work pressure 225 Bar / Maximum 900 Bar) or Hydraulic hose with double steel webbing (Work pressure 400 Bar / Maximum 1600 Bar)
Hydramax 4 and 6: Hydraulic hose with 1 steel webbing (Work pressure 225 Bar / Maximum 900 Bar)
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2.2 Hydramax Cylinders
Cylinder 1000 802-05011
Cylinder 500 802-05009
31
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INSTALLATION
3.1
Installation Axces Connect
There are two types Axces Connect available to connect the roof to the cylinders of the lifting system:
Type 1 uses a steel bottom adapter that is mounted to the sliding bar with a bolt and nut. Type 2 has a steel bottom plate that is slid inside the hollow sliding bar.
Other than that, both types are installed in the same way. Therefore in this chapter, we use the images of Type 1 to illustrate how the Axces Connect is installed.
TYPE 1
TYPE 2
*
PART NR. Set Connect Type 1 144-10095
PART NR. Set Connect Type 2 144-10247
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STEP 1 First mount the Connect tube using the supplied M-lock rivets (st/st Ø6,4x14,2 range 2-9,5mm) into the corner profile. These are high-strength rivets with the correct length for mounting; if the rivets are too long, they will block the sliding bar (see next page) .
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VERSUS-OMEGA Nijverheidslaan 1527A 3660 Opglabbeek - BELGIUM
T: +32 (0) 89 320 190 F: +32 (0) 89 320 199 www.versus-omega.com info@versus-omega.com
PRODUCTINFO
Step2: Assemble the sliding bar. a. start by assembling the bottom adapter onto the sliding bar. b. slide it into the tube and assemble the top adapter onto the sliding bar. Slide the bar in the tube and finish by mounting the top adapter to the bar using an allen screw M8x25 and M8 locknut. STEP 2 Next, mount the bottom adapter to the sliding bar using an allen screw M8x25 and M8 locknut.
B
A
A
A
A
B
A-A
Pay attention to use rivits that are not to long, sliding bar has to be able to move freely up and down. Pay attention to use rivits that are not too long, sliding bar has to be able to move freely up and down.
This drawing, or parts thereof, may not be reproduced in any form, by any method, for any purpose, without the permission of Versus.
Instructions for mounting Hydraman.
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STEP 3 Depending on the type you ordered, the bracket (listed as part 1 in the drawing below) will be included seperately in the set or already welded to the mounting plates of the roof. If you are using your own mounting plates, you need to weld these to the bracket (listed as part 1 in the drawing below) .
When assembling, please pay attention to the remarks in the frame below!
If you need to shorten the sliding bar, please make sure that the minimum distance between the bottom adapter and the tube is still larger than the lifting height of your lifting system! A
The spring-type pin (listed as part 2 in the drawing below) will block the hinge when installed, so please note the following:
B
ONLY mount the spring-type pin (listed as part 2 in the drawing below) if the structure is flexible and can move when lifting the roof, for example in case of lifting systems mounted in back pillars. These pillars can bend slightly when lifting the roof because the back doors are open. In this case, the hinges need to be blocked because otherwise there will be too much flexibility in the system. NEVER mount the spring-type pin (listed as part 2 in the drawing below) on the hinges of lifting systems that are fitted to fixed structures which can’t move when lifting the roof. This is for example the case with lifting systems installed to the front wall; since the front wall is not flexible, the hinges MUST NOT be blocked to prevent putting too much stress on the mechanical parts.
A
B
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3.2 Installation Cylinder 500/1000
STEP 1 Check if the piston of the cylinder is completely down by pushing it in completely at the top.
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STEP 2 Place the cylinder in the corner profile and slide the piston in the middle hole of the bottom adapter of the sliding bar. Push the cylinder upwards until stop, then lower the cylinder about 2-3 mm for the correct mounting position. The 2-3 mm gap ensures that the weight of the roof is never resting on the piston of the cylinder when the roof is down.
Move the cylinder up as far as possible
Lower the cylinder 2 - 3 millimeters
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STEP 3 Mark the position of the two holes on the mounting bracket of the cylinder.
Remove the cylinder and the bracket from the pillar and drill two holes Ø 9 mm.
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STEP 4 Mount the cylinder using the two M8x16 bolts and two spring washers M8.
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STEP 5 Place the clamp over the cylinder, mark the mounting holes and drill Ø 7 mm.
Mount the clamp using the two M-lock rivets (st/st Ø 6,4x14,2 range 2-9,5 mm) included in the set.
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In case of Axces Connect Type 2 , also ensure there is a gap of 2-3 mm between the piston and the steel bottom plate of the sliding bar, as shown in the drawing below.
2-3mm gap
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3.3 Installation Hydramax pump unit
Fill the oil reservoir with three liters of suitable hydraulic oil (HLP 46 or 68).
Mount the Hydramax pump-unit horizontally with the oil reservoir filling hole pointing upwards.
Side view
Mount the pump unit using hexagonal bolts M10 in the mounting channels of the body.
Depending on the set-up of your vehicle, you can choose to mount the pump unit using the top channels (pictured as option 1) or using the side channels (pictured as option 2).
OPTION 1
OPTION 2
100
Front view
Front view
Dimensions
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3.4 Connecting and filling the system
STEP 1 Connect the hydraulic outputs of the pump unit to the cylinders using suitable hydraulic hoses (see specifications).
Hydraulic outputs
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3.5 STEP 2
Install the switch on an easy accessible spot. In case you want to install two Hydramax 2 systems, you will also have two switches, one for each pump unit to be able to lift both sides of the roof separately.
The switch has got five connection ports; connect them according to the schematic below using Ø 8 mm pneumatic hose.
Ports 3 and 5 are air outlets, connect a piece of air hose of minimum 1,5 m long to each one and install a damper at the end of both hoses to reduce noise. Fix the end of the hoses in such a way that the dampers are positioned below the operating switch and pointing downwards so no water or dirt can enter the system.
Be aware of the maximum permitted pressure for the air supply: 10 bar for Hydramax 4 and 6, 6 bar for Hydramax 2. Use a pressure regulator to reduce if necessary.
4 2
51 3
Air supply: Hydramax 2: max 6 bar Hydramax 4 & 6: max 10 bar
Minimum hose length: 1,5m
Install a damper at the end of each hose and position the end of the hoses below the switch with the dampers facing downwards
PART NR. 802-07005
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STEP 3 It is highly recommended to wear protective eyewear during the following filling and bleeding procedure.
To fill the system with oil, hold the lever of the switch in the position that connects the air supply to port number 2 (DOWN position).
In this position, compressed air is directed to the top connector of the pump unit which will push the internal air piston backwards (or roof down). At the same time, this will put pressure on the oil tank so the oil will start flowing through a bypass to the cylinders.
4 2
513
It can take a few minutes to completely fill the hydraulic circuits.
After filling, hold the lever in the UP position (air supply to port number 4) ; the pistons of all cylinders will now rise and the roof will go up:
If all pistons extend fully, proceed to step 4.
Ì
Ì If the pistons don’t reach maximum height, repeat the filling procedure by holding the lever in the DOWN position again.
The roof will descend and the system will start filling the hydraulic circuits again. After a few minutes, check once again if the roof rises completely by holding the lever in the UP position.
Ì If the roof goes up further than before but not completely, repeat the filling procedure.
Ì If the roof doesn’t go up further than the first time, check the oil level in the reservoir by flipping the lever in the DOWN position again to let the roof descend.
When the roof is completely down, check the oil level in the reservoir (continued on next page)
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Be careful when removing the oil reservoir filling screw because there will still be air pressure in the oil tank!
Hold the screw (listed as part 1 in the drawing below) and slowly loosen it to let the air escape before removing it completely. Or you can carefully disconnect the air hose next to the filling screw (listed as part 2 in the drawing below) until no more air escapes and reconnect afterwards, as this will have the same effect.
2
1
If the oil level is low, you should refill to a few centimeters below the top of the reservoir and close it.
Repeat the filling procedure until the roof goes up completely.
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3.5 STEP 4
Lift the roof completely , then bleed the air from the hydraulic circuits by releasing the air bleed screw of one cylinder by one turn with allen key 5 until no more air but only oil escapes. Then close the screw again, but don’t remove it completely!
Repeat this procedure for all cylinders.
After bleeding the hydraulic circuits, check the operation of the lifting system. The roof should now go up smoothly and all pistons should rise simultaneously when holding the lever in the UP position (air supply directed to port nr. 4).
A
AIR
Air bleed screw, loosen by 1 turn to let air escape
B
AIR
OIL
C
OIL
CLOSE
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AXCES CONNECT LIFT & DRIVE
The mounting instructions for Axces Connect Lift & Drive are available on demand.
To request the instructions, you can simply send an e-mail to info@versus-omega.com.
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