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Summary of Contents for MULTILIFT ULTIMA S
- 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...
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Page 3: Table Of Contents
Installation Ultima Hooklift 01/2020 Content 1 General 1.1 Suitability 1.2 Before starting the installation 1.3 General safety instructions for the installation work 2 Construction of Ultima Hooklift 2.1 Main components of steel construction S & SL 2.1 Main components of steel construction Z & ZL 2.2 Main components of hydraulic system S &... - Page 4 Installation Ultima Hooklift 01/2020 5 PLC Control system 5.1 Installation of the control system 5.2 Installation of the control unit 5.3 Installation of the trailer tipping “high flow” ULT BASE 5.4 Installation of the pneumatic hook lock / safety latch 6 Accessories 6.1 Dashboard harness 6.2 Top seat control...
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Page 5: General
We very strongly recommend that the truck is equipped with as stiff as possible stabi- lizers (sway bars) on all axles. A closed rear cross beam should be fitted as well! For further information please refer to your local Multilift dealer. Always use personal protective equipment and other safety means during the installation work and while testing the hooklift. -
Page 6: Construction Of Ultima Hooklift
Installation Ultima Hooklift 01/2020 2. Construction of ULTIMA Hooklift 2.1 Main components of steel construction S & SL Hook arm Ultima S Middle frame Rear frame Sub frame Container body supports Hydraulic locking Tipping lock Rear rollers Tool console Ultima SL... -
Page 7: Main Components Of Steel Construction Z & Zl
Installation Ultima Hooklift 01/2020 2. Construction of ULTIMA Hooklift 2.1 Main components of steel construction Z & ZL Tilting hook arm Z Ultima Z Slide frame Z Middle frame Rear frame Sub frame Container body supports Hydraulic locking Tipping lock Rear rollers Tool console Ultima ZL... -
Page 8: Main Components Of Hydraulic System S & Sl
Installation Ultima Hooklift 01/2020 2.2 Main components of hydraulic system S & SL 1. Main cylinders Ultima S 2. Hook arm cylinder 3. Locking cylinder 4. Dual pilot operated check valve 5. Control valve assembly 6. Load holding valve Ultima SL... -
Page 9: Main Components Of Hydraulic System Z & Zl
Installation Ultima Hooklift 01/2020 2.2 Main components of hydraulic system Z & ZL Ultima Z 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. -
Page 10: Main Components Of Control System
Installation Ultima Hooklift 01/2020 2.3 Main components of control system 1. Control unit Ultima FLEX & PRO 2. Adapter cable 3. CAN extension cable 4. Power supply and CAN linking cable 5. I/O module 6. Connection box for sensors 7. Extra harness (optional) 8. -
Page 11: Installation Of Ultima Hooklift
Installation Ultima Hooklift 01/2020 3. Installation of Ultima Hooklift 3.1 Safety precautions for the installation work Before the installation and any welding work is done, make sure that the battery cables of the truck’s electric system are detached or protected according to the truck manufacturer’s instruc- tions. -
Page 12: Levelling The Chassis
Installation Ultima Hooklift 01/2020 3.2 Levelling the chassis It is essential for the quality and correct installation of the hooklift that the chassis is in a com- pletely level position during the installation. Make sure that: The truck chassis is horizontal across its width; use a level to check it. ... -
Page 13: Sub Frame Dimensions S & Z
Installation Ultima Hooklift 01/2020 3.3 Sub frame dimensions S & Z The sub frame profile material EN10149: ULT14-16-18: S500MC ULT21-26-30: S355MC Hooklift type A (in) B (in) C (in) D (in) E (in) R (in) ULT14S 5.71 1.85 4.45 4.21 ULT16S46-56 ULT16S55, 59-61 5.71... -
Page 14: Sub Frame Dimensions Sl & Zl
Installation Ultima Hooklift 01/2020 3.4 The sub frame dimensions SL & ZL The sub frame profile material EN10149 S355MC Hooklift type A (in) B (in) C (in) D (in) E (in) F (in) R (in) ULT18 / 21SL 1.93 4.57 4.21 0.24 33.31... -
Page 15: Lifting Hooklift Onto The Chassis
Installation Ultima Hooklift 01/2020 3.5 Lifting the hooklift onto the chassis The hooklift must be lifted with an extra care to avoid any dam- ages during the lifting. The hooklift can be ordered with prein- stalled lifting lugs (MU111553501), with what the lifting can be done safe. - Page 16 Installation Ultima Hooklift 01/2020 The weight of Ultima hooklift includes hydraulic locking but not the oil tank. Hooklift type Weight (lbs) Hooklift type Weight (lbs) ULT14S41 3527 ULT26S63 6151 ULT14S43 3593 ULT26S70 6790 ULT14S46 3660 ULT26S78 7121 ULT14S51 3880 ULT30S53 6107 ULT14S53 4056...
- Page 17 Installation Ultima Hooklift 01/2020 The weight includes hydraulic locking but not the oil tank. NOTE! The tool console in front of the hooklift is increasing the total weight approx. 265 lb and moves the center of gravity more forward. Hooklift type Weight (lbs) Hooklift type Weight (lbs)
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Page 18: Releasing Pressure From Main Cylinders
Installation Ultima Hooklift 01/2020 3.6 Releasing pressure from main cylinders There can be some oil pressure in main cylinders that might slightly bend the subframe of the hooklift. Before the mounting plates are installed the pressure must be released. This is done by feeding +24V power to the floating valve solenoid 122 on left side main cylinder. -
Page 19: Installation Plates
Installation Ultima Hooklift 01/2020 3.7 Installation plates The installation plate kits are available to various truck chassis models. The standard kit is meant to hooklift lengths max 59. For the longer hooklifts additional plate kits are available and they usually follow the hooklift delivery. The installation plate kit contains the flexible brackets 2-4 pairs for the front part of the hooklift and the fixed plates for the middle and rear part of the hooklift. - Page 20 Installation Ultima Hooklift 01/2020 Examples of flexible brackets All metal lock nut M14 Some chassis plate types DIN 980 cl.10 need drilling of holes! Washer M14 DIN 125A HB200 Hexagonal screw M14 M16 chassis fasteners requested DIN931 10.9 by some truck manufacturers! Tightening torque for M14 bolt is 125 ft-lb Tightening torque for M16 bolt is 203 ft-lb Hexagonal screw M16 x 110 DIN931 8.8...
- Page 21 Installation Ultima Hooklift 01/2020 Examples of fixed plates All metal lock nut M14 DIN 980 cl.10 Washer M14 DIN 125A HB200 M16 chassis fasteners requested Hexagonal screw M14 DIN931 10.9 by some truck manufacturers! Tightening torque for M14 bolt is 125 ft-lb Tightening torque for M16 bolt is 203 ft-lb Hexagonal screw M14 DIN931 10.9 Example of rear plates...
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Page 22: Installing Additional Cross Member
Installation Ultima Hooklift 01/2020 3.8 Installing the additional cross beam An additional light crossbeam MU113760101 may be used in case subframe front side needs additional support. Install the cross beam with the first flexible bracket... -
Page 23: Helping Cylinder For Tipping Ult26S70/78, Ult30S, Ult26Z
Installation Ultima Hooklift 01/2020 3.9 Helping cylinder for tipping in ULT26S70/78, ULT30S and ULT26Z The helping cylinder beam is delivered loose in the installation kit and it should be installed to the subframe in the area between the middle body support beams shown in the picture below. 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. -
Page 24: Helping Cyl. Hydraulics 26S70/78, 30S, 26Z Flex & Pro
Installation Ultima Hooklift 01/2020 3.9.1 Hydraulic connections of helping cylinder in ULT26S70/78, ULT30S and ULT26Z Ultima Flex & Pro After installation of the helping cylinder cross member connect the pressure hose In the side of the control valve to the elbow connector. Remove the plug from the connector and connect the hose. - Page 25 Installation Ultima Hooklift 01/2020 CV side front CV front corner 110035403 Male stud connector 110035503 Swivel male stud 110035405 Male stud connector 113394201 2-way solenoid valve NO dual check with PRV 4351 psi...
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Page 26: Helping Cyl. Hydraulics 26S70/78, 30S Base
Installation Ultima Hooklift 01/2020 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. -
Page 27: Hydraulic System
Installation Ultima Hooklift 01/2020 4 Hydraulic system 4.1 Safety precautions when installing hydraulic system The hydraulic system may only be installed by qualified personnel. Observe the utmost cleanliness (16/13 ISO 4406) while installing the hydraulic compo- nents. All hoses, pipes etc. components must be cleaned and free from machining an cutting burrs which can cause damage or malfunction to the hydraulic system. - Page 28 Installation Ultima Hooklift 01/2020 ULT14S ULT16S ULT18S ULT18Z Working pressure max. 4351 4351 4351 4351 gal/ Oil flow, recommended Oil tank volume 20-53 20-53 20-53 20-53 Oil volume of hooklift 13-17 17-21 17-21 20-25 Total oil volume 33-70 37-74 37-74 40-78 Suction hose Ø...
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Page 29: Hydraulic Connections Ultima Base
Installation Ultima Hooklift 01/2020 4.3 Hydraulic connections ULTIMA BASE Connect the suction hose from oil tank to pump with 2 ½” suction hose. 3” hose is recommend- ed if pump size is 30 gal/min or larger. Keep the length of the hose as short as possible and install the oil tank higher than the pump. -
Page 30: Hydraulic Connections Ultima Flex & Pro
Installation Ultima Hooklift 01/2020 4.4 Hydraulic connections ULTIMA FLEX & PRO Connect the suction hose from oil tank to pump with 2 ½” suction hose. 3” hose is recommend- ed if pump size is 30 gal/min or larger. Keep the length of the hose as short as possible and install the oil tank higher than the pump. -
Page 31: Hydraulic Pump Installation
Installation Ultima Hooklift 01/2020 4.5 Hydraulic pump installation Before installing the pump check the pump manufacturer’s instructions for the dimensions, oil flow, torque, power and rotation speed and direction. The recommended oil flow and working pressure of the hooklift can be checked in the table in page 28. Under-sizing the pump will cause to too slow operation of the hooklift and over-sizing the pump will cause unnecessary warming up of oil. - Page 32 Installation Ultima Hooklift 01/2020 Tools: - 6 mm hex key - Torque wrench Recommended tools: - 8 mm hex key - Clamp - 2 x M8x50 bolts Remove the upper bolt with 6 mm hex key. Install clamp to hold the cap, make sure the clamp is able to open about 1-1½”. Remove rest of the bolts.
- Page 33 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.
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Page 34: Oil Tank
Installation Ultima Hooklift 01/2020 4.7 Oil tank The oil tank should be installed as high as possible, so that the oil level in the tank will always be higher than the pump inlet level. The suction hose (2½” - 3”) from oil tank to the pump and return line (1”) must be kept as straight and short as possible. - Page 35 Installation Ultima Hooklift 01/2020 Oil tank dimension, steel tanks...
- Page 36 Installation Ultima Hooklift 01/2020 Oil tank dimension, aluminium tanks...
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Page 37: Hydraulic Oil
Installation Ultima Hooklift 01/2020 4.8 Hydraulic oil Before filling up the oil check the interior of the oil tank for impurities and rust. Fill the tank up to the maximum level shown in the oil level gauge. Carefully operate all the hooklift cylinders fully in and out 4 to 5 times to remove the air from the hydraulic system. -
Page 38: Plc Control System
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 below 18 V or gets over 30 V. Over and under voltage errors are logged and can be examined with the service tool’s diagnostics tool. - Page 39 Installation Ultima Hooklift 01/2020 The 3.2 ft adapter cable must be connected to the control unit! The control system does not work without it! Adapter cable Preinstalled in the factory Before any welding job disconnect the connectors from the I/O module! Truck interface CAN cable (1)+...
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Page 40: Installation Of The Control Unit
NOTE! In case of Ultima Flex or Pro, check the possibility to utilize the truck interface cables for the connections of the cabin controller to reduce installation time. Instructions for Scania and Volvo can be found in Multilift Product Site. M12 adapter cable L=3.2 ft... - Page 41 Installation Ultima Hooklift 01/2020 Install the cable from hooklift through the existing holes in the cabin and check the 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.
- Page 42 Installation Ultima Hooklift 01/2020 2GCC Bracket, Basic, Fixed Controller bottom screw 4 x M4x10 Max torque 1,1 (+0,4) ft-lb 113170001 Basic Bracket, Fixed 2GCC Handle Bracket, Fixed 112992201 Base plate 113170201 Handle Bracket...
- Page 43 Installation Ultima Hooklift 01/2020 2GCC Armrest 113170101 Armrest 2GCC Basic Bracket, Removable 112992301 Magnet Bracket 113147901 Base Bracket 2GCC Handle Bracket, Removable 112992301 Magnet Bracket 113170201 Handle Bracket...
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Page 44: Installation Of The Trailer Tipping "High Flow" Ult Base
Installation Ultima Hooklift 01/2020 5.3 Installation of the Trailer tipping ”High flow” ULTIMA BASE Before installing the pneumatic system check the truck manufacturer’s instructions on the cor- rect connection and the system pressure. The working pressure of the hooklift components is 100 psi. -
Page 45: Installation Of The Pneumatic Hook Lock / Safety Latch
Installation Ultima Hooklift 01/2020 5.4 Installation of the Pneumatic hook lock / safety latch Before installing the pneumatic system check the truck manufacturer’s instructions on the cor- rect connection and the system pressure. The working pressure of the hooklift components is 100 psi. -
Page 46: Accessories
Installation Ultima Hooklift 01/2020 6 Accessories 6.1 Dashboard harness (Optional in Ultima Flex & Pro) The dashboard harness is used to connect additional warning lights, warnings buzzer or other signal information into the dashboard of the truck. If the hooklift is delivered with the dashboard harness there is a 33 ft 5-wire M12 cable included in the packing box. -
Page 47: Top Seat Control
Installation Ultima Hooklift 01/2020 6.2 Top Seat Control (Optional in Ultima Flex & Pro) Top seat control allows the user to operate hooklift from loader crane cabin or other location. Top seat control module is preinstalled and parameters are set in the control system. The top seat controller (1) or alternative controller cable (2) without controller are located in the packing box. -
Page 48: External Control
Installation Ultima Hooklift 01/2020 6.3 External Control (Optional in Ultima Flex & Pro) External controls option allows the user to operate hooklift with another controller for instance a loader crane controller. External controls harness is preinstalled and parameters are set to the control system. -
Page 49: Stop Button
Installation Ultima Hooklift 01/2020 6.4 Stop button The power feed stop button is cutting the power feed to the hooklift and is connected between the power feed cable inside the cabin. Stop button Power feed to hooklift 10 A fuse in the truck power feed system (KL15) 111694001 Stop button, inside... - Page 50 Installation Ultima Hooklift 01/2020 111694002 Stop button, outside 111694003 Emergency stop, outside with memory circuit...
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Page 51: Working Lights
Installation Ultima Hooklift 01/2020 6.5 Working lights Install the relay box near the control valve and the working lights to the connection bridges in- side the box. Then connect the JPT connector to the connector 1.21 in the valve harness or in case of helping cylinder is equipped, to connector 2.17 in the extra harness. -
Page 52: Rear View Camera Control Connections
Note! Do NOT use the cables included in the camera switch box. Always use only the MULTILIFT cables! M12 T-splitter CAN extension cable CC adapter cable 3.2 ft Flex display adapter cable 10 ft Camera switch box power &... - Page 53 The display adapter cable is connected to the camera switch box, to 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! Connector to Flex Display M12 connector to splitter in...
- Page 54 Installation Ultima Hooklift 01/2020 Camera switch box power connections 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 Installation Ultima Hooklift 01/2020 Camera and display connections The cameras are connected to the camera switch box with the 65 ft extension cables and 8” adapter cables as follows: Rear rollers camera Rear bumper camera Extension Left Right cable MU113992701 Adapter cable Back...
- Page 56 Installation Ultima Hooklift 01/2020 Camera view examples High Bogey Rear...
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Page 57: Connectivity Gateway Antenna
Installation Ultima Hooklift 01/2020 6.7 Connectivity gateway antenna The gateway antenna is delivered loose in the packing box and the antenna bracket is installed in front of the left side subframe beam. Exception is the hooklift with tool console where the antenna is preinstalled in the factory. - Page 58 Installation Ultima Hooklift 01/2020 Antenna and connection cable The length of the antenna cable depends on the control valve (CV) position and the G-length of the hooklift. For the Ultima hooklifts with G-length >=61 there is an extension cable delivered with the unit.
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Page 59: Testing The Hooklift
Installation Ultima Hooklift 01/2020 7 Testing the hooklift 7.1 safety precautions when testing the hooklift Always use personal safety protections when testing the hooklift. High pressure oil leaks can be life threatening, especially direct sprays of oil. Never touch the hydraulic components under pressure and therefore stay clear from the hydraulic system. - Page 60 Installation Ultima Hooklift 01/2020 With the truck engine idling check the setting of the by-pass valve by checking to see that the container locks are opening and closing without a delay and that the hook arm is moving front and back. If the locks or hook arm (as well as any of accessories) are not moving, close the by -pass valve to increase flow to the hydraulic actuators.
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Page 61: Finishing The Installation
Installation Ultima Hooklift 01/2020 8. Finishing the installation Protect all electric connections and check the greasing points. Finish all welding and surfaces of the cut plate edges. Clean all excess lubricants and remove all welding sparks and protection agents. Wash the hooklift and other components thoroughly before touch-up painting. As standard the hooklift is delivered from factory painted with 100 µm single layer polyurethane top coat according to standard PUR 100/1 FeSa 2½. - Page 62 Installation Ultima Hooklift 01/2020...
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