MULTILIFT ULTIMA S, Installation Instructions Manual

Page 1: ...INSTALLATION INSTRUCTIONS MULTILIFT ULTIMA S SL Z ZL Hooklift Base Flex Pro US edition 01 2020 ...

Page 2: ...Installation Ultima Hooklift 01 2020 2 ...

Page 3: ...velling the chassis 12 3 3 Sub frame dimensions S Z 13 3 4 Sub frame dimensions SL ZL 14 3 5 Lifting hooklift onto the chassis 15 3 6 Releasing pressure from main cylinders 18 3 7 Installation plates 19 3 8 Installing additional cross member 22 3 9 Helping cylinder for tipping ULT26S70 78 ULT30S ULT26Z 23 3 9 1 Helping cyl hydraulics 26S70 78 30S 26Z FLEX PRO 24 3 9 2 Helping cyl hydraulics 26S70 ...

Page 4: ...llation of the pneumatic hook lock safety latch 45 6 Accessories 46 6 1 Dashboard harness 46 6 2 Top seat control 47 6 3 External control 48 6 4 Stop button 49 6 5 Working lights 51 6 6 Rear view camera control connections 52 6 7 Connectivity gateway antenna 57 7 Testing the hooklift 59 7 1 Safety precautions when testing the hooklift 59 7 2 Testing the hooklift 59 8 Finishing the installation 61 ...

Page 5: ...tioning on the chassis and installation drawings are available Check that the truck manufacturer s installation instructions are available 1 3 General safety instructions for the installation work Ultima Hooklift may only be installed by qualified and trained personnel Ultima Hooklift can be installed only on suitable truck chassis which is designed for hooklift or tipper use and is allowed to car...

Page 6: ... ULTIMA Hooklift 2 1 Main components of steel construction S SL Ultima S 1 Hook arm 2 Middle frame 3 Rear frame 4 Sub frame 5 Container body supports 6 Hydraulic locking 7 Tipping lock 8 Rear rollers 9 Tool console 1 2 3 4 5 6 7 8 Ultima SL 1 2 3 4 5 6 7 8 9 ...

Page 7: ... 2 1 Main components of steel construction Z ZL Ultima ZL Ultima Z 1 Tilting hook arm Z 2 Slide frame Z 3 Middle frame 4 Rear frame 5 Sub frame 6 Container body supports 7 Hydraulic locking 8 Tipping lock 9 Rear rollers 10 Tool console 1 2 3 4 5 6 7 8 9 10 1 2 3 4 5 6 7 8 9 ...

Page 8: ...1 2020 8 2 2 Main components of hydraulic system S SL Ultima S Ultima SL 1 Main cylinders 2 Hook arm cylinder 3 Locking cylinder 4 Dual pilot operated check valve 5 Control valve assembly 6 Load holding valve 2 1 5 3 4 6 1 2 3 4 5 6 ...

Page 9: ... components of hydraulic system Z ZL Ultima Z Ultima ZL 1 Main cylinders 2 Slide arm cylinder Z ZL 3 Locking cylinder 4 Dual pilot operated check valve 5 Control valve assembly 6 Load holding valve 7 Tilting cylinder Z ZL 2 1 5 3 6 7 1 2 3 4 4 5 6 7 ...

Page 10: ... cable 4 Power supply and CAN linking cable 5 I O module 6 Connection box for sensors 7 Extra harness optional 8 Valve harness 9 Dashboard harness optional 10 Radio transmitter 2GRC optional 11 Mini Radio 2GMR optional 12 Radio Receiver optional 13 Control unit Ultima BASE 1 2 3 6 7 8 Preinstalled in the factory 24V GND 5 4 9 10 11 12 2 13 ...

Page 11: ...ore welding To prevent fire make sure before welding flame cutting and grinding that sparks can not fly onto oil or fuel etc in or around the assembly The truck cabin must be protected well before any installation work The cabin must always be fully tilted if applicable up to the mechanical lock before work is carried under it Check the truck manufacturer s instructions for tilting the cabin Befor...

Page 12: ...truck chassis is horizontal across its width use a level to check it Both chassis beams are aligned All wheels are straight forward Tire pressures are correct Lift axles and bogie are down all wheels must be firm on ground There is no hole or drain cover under any wheel For levelling an air suspension axles the air bags must be deflated and the rear end must be supported Remember to level that cha...

Page 13: ... in B in C in D in E in R in ULT14S ULT16S46 56 5 71 1 85 4 45 4 21 0 2 0 2 ULT16S55 59 61 ULT18S Z 5 71 1 89 4 45 4 21 0 24 0 24 ULT21S Z ULT24S ULT26Z 6 5 1 93 4 76 4 21 0 31 0 31 ULT26S ULT30S 6 5 1 93 4 76 4 21 0 31 0 31 Hooklift type A sub frame in2 Wx top flange in3 e top flange in Wx bottom fl in3 e bottom fl in Ix in4 ULT14S ULT16S46 56 5 9226 12 5773 2 64 10 1166 3 07 32 0071 ULT16S55 59 ...

Page 14: ...L 9 7588 22 4813 2 87 17 8327 3 62 64 6000 The values in the next table are calculated with both side Z beams and standard amount of cross members when the beams are working together If the value is needed only for one beam then the value can be halved Hooklift type A in B in C in D in E in R in F in ULT18 21SL 6 5 1 93 4 57 4 21 0 24 0 24 33 31 ULT22 24 26SL ULT20 24ZL 6 5 1 93 4 57 4 21 0 31 0 3...

Page 15: ...hooklift can be lifted from the body supports and rear rollers Lifting from the hook arm the middle frame or the rear frame is not allowed due to the risk of damages Before lifting check to be sure that no hy draulic or electric components can be damaged The centre of gravity of the hooklift is approx 55 of the G length measured from rear rollers towards front Always check the condition and operat...

Page 16: ... 4453 ULT18S61 4497 ULT21S46 5049 ULT21S51 5247 ULT21S53 5445 ULT21S56 5511 ULT21S59 5578 ULT21S61 5622 ULT21S63 5710 ULT24S55 5556 ULT26S51 5622 ULT26S53 5842 ULT26S55 56 5908 ULT26S59 6019 ULT26S61 6063 Hooklift type Weight lbs ULT26S63 6151 ULT26S70 6790 ULT26S78 7121 ULT30S53 6107 ULT30S56 6151 ULT30S59 6283 ULT30S61 6327 ULT30S63 6415 ULT18Z46 5026 ULT18Z51 5203 ULT18Z53 5313 ULT18Z56 5423 UL...

Page 17: ...ight lbs ULT18SL49 4453 ULT18SL51 4586 ULT18SL52 4696 ULT18SL53 4806 ULT18SL56 4850 ULT21SL49 4497 ULT21SL51 4630 ULT21SL52 4740 ULT21SL53 4850 ULT21SL56 4894 ULT22SL53 5302 ULT22SL56 5346 ULT22SL58 5456 ULT22SL59 5456 ULT22SL61 5478 ULT24SL56 5467 ULT24SL58 5600 ULT24SL59 5600 ULT24SL61 5622 ULT26SL56 5511 ULT26SL58 5644 Hooklift type Weight lbs ULT20ZL53 5688 ULT20ZL56 5842 ULT20ZL58 5930 ULT20Z...

Page 18: ...n cylinder Use adapter cable MU113937001 1 Fuse holder with 5A fuse 2 Battery clamp 24VDC 3 Battery clamp GND 4 Connector 122 for floating valve 1 2 3 4 Version without fast speed Version with fast speed FLOATING 122 If the hooklift is not equipped with preinstalled oil reservoir then open the plug from the tank line connector on the control valve before activating the solenoid and catch up the oi...

Page 19: ...oss member The tightening torque of the vertical M16 8 8 bolts is 22 ft lb turns Some truck manufacturers are requesting to use Belleville springs with vertical bolts in heavy conditions Check truck manufacturer s instruc tions NOTE If the hooklift is equipped with front locking then there must be fixed installation plates underneath the lock First installation plates towards the rear from flexibl...

Page 20: ...s requested by some truck manufacturers Some chassis plate types need drilling of holes Tightening torque for M14 bolt is 125 ft lb Tightening torque for M16 bolt is 203 ft lb Washer M16 DIN 125A HB200 Hexagonal screw M16 x 110 DIN931 8 8 Tightening torque 22 ft lb 1 4 rev Hexagonal screw M16 x 60 DIN931 10 9 Tightening torque 203 ft lb All metal lock nut M16 DIN 980 cl 10 2x 2x 3x 3x ...

Page 21: ...e truck manufacturers Tightening torque for M14 bolt is 125 ft lb Tightening torque for M16 bolt is 203 ft lb 3x 3x 3x 3x All metal lock nut M14 DIN 980 cl 10 Hexagonal screw M14 DIN931 10 9 All metal lock nut M14 DIN 980 cl 10 Washer M14 DIN 125A HB200 M16 chassis fasteners requested by some truck manufacturers Example of rear plates Hexagonal screw M14 DIN931 10 9 Washer M14 DIN 125A HB200 6x 6x...

Page 22: ...Hooklift 01 2020 22 Install the cross beam with the first flexible bracket 3 8 Installing the additional cross beam An additional light crossbeam MU113760101 may be used in case subframe front side needs additional support ...

Page 23: ...w Check that the structural parts in the truck chassis allow free installation and that the hydraulic pipes or connectors under main cylinders do not hit the beam The beam is fastened to the subframe with the M14x40 10 9 bolts included in the kit The tightening torque is 88 5 ft lb In the beam there are alternative holes to move the cylinder about 2 sideways Area to install the helping cylinder be...

Page 24: ...the elbow connector Remove the plug from the connector and connect the hose The tightening torque is 51 6 ft lb The electric connector 121 for the solenoid valve is located near the control valve NOTE Hose fitting and valve must be tilted slightly so that hose fitting does not collide with valve car tridge P T NOTE Valve must be assembled according to drawing Wrong assembly can cause severe materi...

Page 25: ...ion Ultima Hooklift 01 2020 25 CV side front 110035403 Male stud connector 110035503 Swivel male stud 110035405 Male stud connector 113394201 2 way solenoid valve NO dual check with PRV 4351 psi CV front corner ...

Page 26: ... a correct valve type 3 9 2 Hydraulic connections of helping cylinder in ULT26S70 78 and ULT30S BASE After installation of the helping cylinder cross member connect the pressure hose to the piston side line of the main cylinders There is a plugged T connector behind the control valve for this connection Remove the plug and connect the hose The tightening torque is 51 6 ft lb Valve with friction re...

Page 27: ... be handled according to local legislation and instructions The safety data sheet of the hydraulic fluid must be available to the people working with the hydraulic system 4 2 Specifications of the hydraulic system The recommended oil flow and oil volumes for individual hooklift size is shown in the table next page The minimum size of oil tank is equal to one minute pump flow The recommendation is ...

Page 28: ...351 4351 4351 4351 4351 Oil flow recommended gal min 26 26 26 31 31 26 Oil tank volume gal 20 53 20 53 20 53 20 53 20 53 20 53 Oil volume of hooklift gal 21 26 26 30 26 30 28 37 28 37 21 26 Total oil volume gal 41 79 46 83 46 83 48 90 48 90 41 79 Suction hose Ø in 2 2 2 2 2 2 Pressure line Ø In Return line Ø in 1 1 1 1 1 1 ULT18 21SL ULT22 24 26SL ULT20 24ZL Working pressure max psi 4351 4351 4351...

Page 29: ...or 3 4 L 20 in be tween as a vibration damper The high pressure filter is installed between the pump and the control valve The pressure filter is obligatory in Flex Pro hooklifts and highly recommended in Base hooklift Connect the return line from control valve R1 to the return filter and keep the return line as straight and short as possible to avoid unnecessary warming of oil The diameter of the...

Page 30: ...valve The pressure filter is obligatory in Flex Pro hooklifts The pressure filter can be installed vertically or horizontally Change of filter element will be easier with vertical installa tion due to less oil drain Connect the return line from control valve R1 to the return filter and keep the return line as straight and short as possible to avoid unnecessary warming of oil The diameter of the tu...

Page 31: ...ven PTO Alternative pump type is a fixed displacement pump installed on the en gine driven PTO In case of Ultima Flex or Pro a variable displacement pump use is possible Before first start of the pump remember to fill it up with hydraulic oil Check the pump manu facturer s instruction on filling up and other possible procedures 4 6 Variable pump LS line installation Ultima Flex Pro Check from the ...

Page 32: ...1501 L 2 78 70 5 mm 8 Push the plunger in using a bit of force so that the spring goes into its hole 9 Place the cap back and use 2 x M8x50 bolts as a guide Make sure that the red O ring is in place 10 Use clamp to press the plunger in 11 Install 2 bolts and then remove the clamp 12 Install the last bolt and tighten each one using torque wrench Tightening torque 11 8 ft lb 11 8 ft lb Be careful wh...

Page 33: ...o T connector 15 Install proper LS line hose from T connector to the pump LS line hose preinstalled at factory Remove nipple if JIC T connector is used Leave if BSP T connector is used Use Multilift Service Tool to set the parameter XM1 08 DO Supply voltage See also separate instructions ULTIMA LS line configuration pdf and the instruction video in Multilift Product Site ...

Page 34: ...ks with high flow return filter The oil flow capacity for the low flow return filter is 60 gal min and for the high flow filter is 120 gal min The filtration degree for both is 10µm The dimensions of the oil tanks are shown in next page It is important to choose the oil tank location to be accessible for inspection filling and drain ing The oil level checking is a daily routine so visibility of oi...

Page 35: ...Installation Ultima Hooklift 01 2020 35 Oil tank dimension steel tanks ...

Page 36: ...Installation Ultima Hooklift 01 2020 36 Oil tank dimension aluminium tanks ...

Page 37: ...the whole hydraulic system must be drained and flushed several times thoroughly in order to achieve the required cleanliness To obtain the best results the percentage of the mineral oil should not exceed 2 of the oil volume Contact factory for possible bio oil options Procedure for changing the oil type and viscosity class is the following 1 Drain the hydraulic system from existing oil 2 Fill the ...

Page 38: ...on while driving Check the truck manufacturer s instruc tions on connecting the accessories Use existing holes Ø 0 3 in the cabin to draw the cable It is not recommended to take the power directly from the battery because it might run empty in longer period The PLC control system is protected against under and over voltage Multilift control unit will prompt an error message if the voltage lowers b...

Page 39: ...nnect the connectors from the I O module Any self made electrical connections to the cables wires and solenoids are strictly forbidden because they might interfere the CAN signals 1 2 Adapter cable The 3 2 ft adapter cable must be connected to the control unit The control system does not work without it Truck interface CAN cable ...

Page 40: ... closed Make sure the rain does not fall on the control unit when the door is open The M12 male connector in the cable of control unit is connected to the M12 female connector in the cable coming from the hooklift Leave the connectors in a suitable location where they are easy to access for possible software updates Fasten the stand of control unit with screws The angle of control unit can be adju...

Page 41: ...e tightness of lead in If the cabin has tilting mechanism then the cable must be run around the tilting mechanism Check that the cable can t get squeezed in the cabin con struction Power feed 10A Use only free con nection place which does not have other electric devices connected Additional warning lights See 6 1 DB harness ...

Page 42: ... Ultima Hooklift 01 2020 42 2GCC Bracket Basic Fixed 113170001 Basic Bracket Fixed 2GCC Handle Bracket Fixed 112992201 Base plate 113170201 Handle Bracket Controller bottom screw 4 x M4x10 Max torque 1 1 0 4 ft lb ...

Page 43: ...Ultima Hooklift 01 2020 43 2GCC Armrest 113170101 Armrest 112992301 Magnet Bracket 113147901 Base Bracket 2GCC Basic Bracket Removable 2GCC Handle Bracket Removable 112992301 Magnet Bracket 113170201 Handle Bracket ...

Page 44: ...hooklift components is 100 psi The maximum pressure for the pneumatic system is 145 psi Use pressure regulator if needed The solenoid valves Herion where the air feed is connected are located next to the trailer tip ping high flow valve Remember to follow cleanliness guidelines when installing the pneumatic connections 206 Trailer tipping up 205 Trailer tipping down Air feed 100 psi 206 205 Air fe...

Page 45: ...00 psi The maximum pressure for the pneumatic system is 145 psi Use pressure regulator if needed The solenoid valve Herion where the air feed is connected is located next to the main control valve Remember to follow cleanliness guidelines when installing the pneumatic con nections Air feed 100 psi 118 Hook lock open or 218 Hook lock open Note There is a small air leak from the cylinder to keep it ...

Page 46: ...e truck If the hooklift is delivered with the dashboard harness there is a 33 ft 5 wire M12 cable included in the packing box Install the cable into the dashboard warning lights buzzer is located and connect the M12 connector in the bottom of the control unit Adjust the outputs with the service tool software M12 5 pole dashboard harness L 33 ft Wires Brown Output 1 White Output 2 Blue Output 3 Bla...

Page 47: ... 1 or alternative controller cable 2 without controller are located in the packing box Install the controller to a suitable place where it is easy to use The emergency stop is set on as standard When the emergency stop button is pushed down then the text StOP ap pears in the display of the cabin controller When the top seat controller is activated then a text C2 appears in the display Top seat con...

Page 48: ...rane controller External controls harness is preinstalled and parameters are set to the control system Install the cables 1 2 and 3 to the external control system according to the instruction given by the manufacturer When the external controller is activated then a text C2 appears in the display of the cabin controller Preinstalled in the factory 33 ft Extension module External controls harness ...

Page 49: ...utton The power feed stop button is cutting the power feed to the hooklift and is connected between the power feed cable inside the cabin 10 A fuse in the truck power feed system KL15 123 Stop button Power feed to hooklift 111694001 Stop button inside ...

Page 50: ...Installation Ultima Hooklift 01 2020 50 111694002 Stop button outside 111694003 Emergency stop outside with memory circuit ...

Page 51: ...21 in the valve harness or in case of helping cylinder is equipped to connector 2 17 in the extra harness Now connect the relay box power to the truck power supply behind a fuse 10 15A Note Max 8 lights totalling 10A L1 24V To connector 1 21 in the valve harness or to connector 2 17 if helping cylinder is installed Work light cables to individual lights Use own inlet to each lamp 33 ft 3 2 ft Red ...

Page 52: ...lose to each others inside the cabin to a suitable place Note Do NOT use the cables included in the camera switch box Always use only the MULTILIFT cables Flex display adapter cable 10 ft CC adapter cable 3 2 ft M12 T splitter CAN extension cable Flex display Camera adapter cable 3 2 ft Display bracket B red Vehicle power supply 1m fuse 3A GND black 3 2 ft Rear bumper camera Cabin back wall camera...

Page 53: ...the display and to the hooklift control system Note Do NOT use the cables included in the camera switch box Always use only the MULTILIFT cable MU113994801 M12 connector to splitter in hooklift control system Connector to Flex Display Connector to Camera switch box B red to vehicle power supply GND black to ground MU113994801 L 10ft L 3 2ft ...

Page 54: ...onnections Connect the camera switch box power and ground to truck power supply KL15 Red wire marked with B to truck power supply KL15 fuse 3A Black wire marked with GND to ground Read the switch box installation manual included in the packing box before installation ...

Page 55: ...g the roller contact when loading the container Pos sible to show also the hydraulic locking Rear bumper camera CA3 Detailed view when reversing truck closer to the container and helping when attaching hook to the hookbar Camera active when middle frame is 100 deg Camera adapter cable 3 2 ft to display Rear bumper camera Cabin back wall camera Rear rollers camera Left CA2 Back CA1 Right CA3 RCA Mo...

Page 56: ...Installation Ultima Hooklift 01 2020 56 Camera view examples High Bogey Rear ...

Page 57: ...e factory The best place for the antenna is on top and at back of the truck cabin The gateway module is installed on the control valve bracket The illustration below is showing the location of the antenna bracket in new hooklift delivery The correct and suitable location must be checked during the installation before the connectiv ity gateway is taken into use THE ANTENNA SHOULD BE INSTALLED TO A ...

Page 58: ... Antenna and gateway connections Connect the antenna colour coded connectors and the power feed to the gateway module ac cording to the drawing below Gateway Antenna Gateway adapter cable M12 T Splitter 3724 module Connector Description Beige 1 WiFi Blue 2 GPS Violet 3 GSM 1 Description Colour GND Blue 24V continuous current KL30 10A Brown Extension cable L 21 ft The gateway has 7A internal fuse b...

Page 59: ...rained personnel Always vent and fill the pump with oil before starting Check pump manufacturer s instructions The first test run must be performed with extra care because there is air in the system which may cause unexpected movements Observe all movements carefully to prevent any damage possible collisions or friction of parts Make sure you keep out of range of all rotating or moving parts such ...

Page 60: ...vements Accessories When the hydraulic or manual front locks are closed the main cylinders don t move out and the hook arm does not move rear or front Tipping is not allowed if while the Crane body on sensor is active The main cylinders protection circuit is limiting the operation pressure of main cylinder out movement to 1600 psi after middle frame is lifted up over 20º angle When the adjustable ...

Page 61: ... clean steel surface Smoothen the paint edges carefully Check that the surface is clean from dust oil and grease and completely dry for the touch up Paint it with 100 µm layer use of primer is not recommended Use acrylic paint with correct colour check the tone and code RAL carefully before painting Let the paint dry 24 h indoors Check the correct colour from the hooklift order before touch up pai...

Page 62: ...Installation Ultima Hooklift 01 2020 62 ...