MULTILIFT Hooklift XR S Series User manual

MULTILIFT XR S
Hooklift XR3S / XR5S
INSTALLATION INSTRUCTIONS
US
January 2019

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Chapter Page
1 PREPARING FOR INSTALLATION 4
1.1 Before starting installation 4
1.2 General safety precautions during installation 4
2 GENERAL 5
2.1 Main components of XR-unit 5
2.2 Main hydraulic components of XR-unit 6
3 BODYBUILDING 7
3.1 Safety precautions when mounting the hooklift unit 7
3.2 Extra subframe 7
3.3 Before mounting the subframe 8
3.4 Shortening of subframe 8
3.5 Shortening the chassis frame 8
3.6 Mounting fitting plates 10
3.7 Mounting instructions when using Multilift –fitting plates 11
3.8 Multilift –fitting plate series 12
3.9 Mounting instructions when using other plates 20
3.10 Installing of toolbox, spare wheel, sheet rack etc. 21
4 HYDRAULIC SYSTEM 22
4.1 Safety precautions when installing the hydraulic system 22
4.2 Technical information 22
4.3 Hydraulic diagram 23
4.4 Hydraulic layout 23
4.5 Oil tank installation 24
4.6 Pump installation 24
4.7 Hydraulic oil 25
5 CONTROL SYSTEM 26
5.1 Installation of control unit 26
5.2 Installation of wiring loom 26
5.3 Electric system (Basic) 28
5.4 Electric system (Basic plus) 29
6 TESTING THE UNIT 30
6.1 Safety precautions when testing the hooklift system 30
6.2 Testing the XR-unit 30
7 FINISHING 31
7.1 Cleaning vehicle combination 31
7.2 Painting 31
7.3 Finish up attachment 31
8 TRAINING 32

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1. PREPARING FOR INSTALLATION
1.1 Before starting installation
Make sure that the XR-unit to be installed has been checked upon arrival for both transport dam-
age and contents of the delivery.
Check that all the parts are available to complete the installation as planned.
Check the availability of the correct tools and lifting gear during the installation.
1.2 General safety precautions during installation
Multilift XR demountable body lifting equipment may only be installed by qualified personnel.
XR-unit can only be installed on suitable truck chassis. Normally chassis have to be meant for tip-
ping use.
Before installation and preferably before sale of the equipment, calculations should be made in-
cluding gross vehicle weight, axle weight and any other weights and dimensions needed to en-
sure the overall economy of the combination.
Maximum permitted GVW and capacity of the unit must be in proportion to each other, and neither
should be exceeded. Exceeding either maximum GVW or capacity may result in physical injury or
material damage.
When installing the unit it must be ensured that the keys of the vehicle are in the possession of
the person carrying out the installation.
During installation, a fixed working light is to be installed for operating with demountable body in
dark or poorly lighted conditions.
In all installation work general safety rules must be followed. Further information on these can be
obtained from occupational safety personnel and the employer.

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1. Sliding arm
2. Middle frame
3. Hydraulic body locking (additional)
4. Rear roller
5. Rear frame
6. Tipping lock
7. Sub frame
2 GENERAL
2.1 Main components of XR-unit
Steel contructions:

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1. Main cylinder
2. Hookarm cylinder
3. Hydraulic body locking cylinder (additional)
4. Control valve
5. Oil tank
2. GENERAL
2.2 Main components of XR-unit
Hydraulic components:

3 BODYBUILDING
3.1 Safety precautions when mounting
the hooklift unit
Before any welding work is done, make sure
the battery cables of the vehicle’s electrical
system are detached. Check always instruc-
tions of chassis manufacturer, how the de-
tach of battery can be done and what else
should be noticed.
To prevent fire, make sure before flame cut-
ting or welding that sparks can’t fly onto oil
etc. in or around the unit.
The truck cabin must be protected well be-
fore any mounting work of hooklift.
The hooklift system may only be lifted by
body supports of subframe and rear rollers.
Check the condition and fastening of all
hooks before lifting.
Check the condition and fastening gear
before lifting. Also notice the maximum
weight of the hooklift system, and the
maximum capacity of the gear lift.
3.2 Extra subframe
Check if components like change gear box,
cross members, and brake boosters (in high-
est position) project beyond the truck chas-
sis. If these components contact container
system elements, either remove them, if pos-
sible, or use extra subframe over the whole
chassis frame length.
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Type
G-measure
2700 2950 3200
XR2S
860 900 950 lb
XR3S
880 925 970 lb
Type
G-measure 3250 3650 4150
XR5S
1480 1565 1650 lb
XR7S
2050 2120 2185 lb
XR8S
2160 2230 2295 lb
Unit weights

3.3 Before mounting the subframe
•Check that vehicle chassis is horizontal
across its width
-Use a level
•Set all wheels to straight forward
•Make sure the tyre pressure is correct
•If the vehicle is equipped with one or
various facilities for prolonged reduction
in load on a shaft or wheel, such as a
lifting axle or trailing axle, all wheel
should rest on the ground.
3.4 Shorten the subframe front
members
Shorten the subframe front members to the
correct length before lowering the unit onto
the vehicle. The subframe should come as
far forward as possible, in any case in front
of the front spring rear bracket. Cutting
should be done in accordance with the adja-
cent drawing.
Note that the cut edge of the lower flange
should be rounded off (see drawing).
3.5 Shortening the chassis frame
The vehicle manufacturer may have given
specific instructions (in the manual for install-
ing accessories) for choosing the cut-points
for the vehicle. These instructions may in-
clude information about the rear spring
brackets, anti-roll bars, cross-beams in the
rear of the frame etc.
The chassis frame should be cut 3in behind
the centerline of the rear roller shaft
(see drawing). There should remain a mini-
mum clearance of 3in between the cab and
the unit
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3"

The general principle is that the rear over-
hang should be kept to the minimum.
The aim is to position the unit longitudinally
so that the center of gravity of the fully
loaded body coincides with the center of
gravity of the load on the vehicle loaded to
full GVW.
Ensure before cutting the chassis that elec-
tric and hydraulic lines will not be damaged
and that the relocating of the chassis rear
cross member and rear light assembly is al-
lowed for and that the vehicle manufacturer’s
instructions for shortening the chassis are
followed.
See also superstructure welding
instructions of chassis manufacturer.
Extending chassis rear overhang
If the truck chassis frame is shorter than the
hooklift system, it should be extended.
See also superstructure welding instructions
of chassis manufacturer.
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3.6 Where to put mounting plates?
Please observe any instructions given by the vehicle manufacturer, which will affect the follow-
ing Multilift installation instructions.
Multilift has available a variety of installation kits to suit a range of popular trucks (or vans).
These kits include the necessary brackets, nuts and bolts to complete installation. The quality
of bolts is 8.8 or 10.9 depending on vehicle manufacturers instructions. In Multilift mounting kits
quality of the bolts are 8.8.
The subframe brackets are mounted to the chassis using the M12hexagonal bolts and SL-nuts
included in the installation package. The number of bolts used is very important, the minimum
number of bolts per bracket shown in the table should thus be carefully observed. Locate the
brackets as near cross members of subframe as possible. Existing holes in the subframe
should be used.
The following figure shows example at which
intervals to attach the plates.
Bracket Quantity Fixing bolts in
subframe
Fixing bolts in
chassis frame
1 Rear end retainer plate 1 pair 3 pcs M126 pcs M12
2 Large rear retainer plate 1 pair 4 pcs M128 pcs M12
3 Retainer plate 3...4 pair 2 (4) pcs M122 pcs M12
4 Front retainer plate 1 pair 2 pcs M122 pcs M12

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3.7 Mounting instructions when using other plates
Use the existing holes in the chassis frame wherever possible. Choose the dimensions of the
large rear retainer plate and shape the plate so that the plate can hold the minimum number of
screws with required distances despite the bracket of rear spring or other such parts. (Drawing)
Drill holes of fitting bolts to fitting plates and to the chassis frame if necessary.
About drilling of holes
•Before drilling holes trough the chassis frame, ensure that no damage will result to any tubes
or wiring etc.
•Drill holes as necessary in the chassis members. It’s recommended to use an undersized drill,
0,47 in (11,9 mm)drill for M12 bolts, so that a play free joint is ensured.
•Never drill holes in the flanges of the side members.
•Never weld filler pieces in the holes of the chassis frame.
•Drilled holes must always be de-burred and treated with primer / paint.
Mount and tighten the bolts and SL-nuts of retainer plates.
The torque of M12 bolts is 85 Nm
Mount to rear end plate subframe by three bolts and SL-nuts.
Lower the XR-unit subframe onto the chassis (or the additional subframe) and check it’s exact
longitudinal location and center it in relation to the chassis. Once the hooklift system is accurately
positioned, fix it to the vehicle chassis using clamps.
Fix the retainer plates to the subframe using M12-bolts and SL-nuts. Weld the rear end retainer

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Iveco Daily
No. 110983801
3.8 Multilift-kiinnityslevy sarjat, XR-5

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Mitsubishi Canter
No. 110770501

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MB Ateco 818 / 823
No. 110838801

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MB Ateco 1223
No. 110840401

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 
Volvo FL612
No. 110996501

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 
MAN L2000
No. 110842301

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 
Renault Mascott
No. 110838001

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Renault Midlum
No. 110732401