MULTILIFT ULTIMA S User manual

INSTALLATION INSTRUCTIONS
MULTILIFT ULTIMA S/SL & Z/ZL Hooklift
Base, Flex & Pro US edition
01/2020

Installation
Ultima Hooklift 01/2020
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Installation
Ultima Hooklift 01/2020
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Content
1 General 5
1.1 Suitability 5
1.2 Before starting the installation 5
1.3 General safety instructions for the installation work 5
2 Construction of Ultima Hooklift 6
2.1 Main components of steel construction S & SL 6
2.1 Main components of steel construction Z & ZL 7
2.2 Main components of hydraulic system S & SL 8
2.2 Main components of hydraulic system Z & ZL 9
2.3 Main components of control system 10
3 Installation of Ultima Hooklift 11
3.1 Safety precautions for the installation work 11
3.2 Levelling 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 26S70/78, 30S BASE 26
4 Hydraulic system 27
4.1 Safety precautions when installing hydraulic system 27
4.2 Specifications of the hydraulic system 27
4.3 Hydraulic connections ULTIMA BASE 29
4.4 Hydraulic connections ULTIMA FLEX & PRO 30
4.5 Hydraulic pump installation 31
4.6 Variable pump LS line installation 31
4.7 Oil tank 34
4.8 Hydraulic oil 37

Installation
Ultima Hooklift 01/2020
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5 PLC Control system 38
5.1 Installation of the control system 38
5.2 Installation of the control unit 40
5.3 Installation of the trailer tipping “high flow” ULT BASE 44
5.4 Installation 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
9 User training 61

Installation
Ultima Hooklift 01/2020
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1. General
These Hooklift Installation Instructions will give the basic information on the installation of the
hooklifts.
1.1 Suitability
These instructions are meant for the following Ultima Hooklifts S, SL, Z and ZL with Base, Flex
or Pro control system.
1.2 Before starting the installation
Make sure that the Ultima Hooklift to be installed has been checked upon arrival for both
transport damage and contents of the delivery including the kit box.
Check that all the parts are available to complete the installation as planned.
Check that the correct tools and proper lifting gear is available and in good condition.
Check the actual weight of the chassis by weighing it.
Check that the axle weight distribution calculation (TrailerWin) for correct positioning 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 carry the maximum load of the hooklift.
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.
Due to continuous development some of the illustration may look different to the one used in
the hooklift.
Cargotec Finland Oy reserves all rights for this manual.
Cargotec Finland Oy
Raisio
2020

Installation
Ultima Hooklift 01/2020
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2. Construction of 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

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2. Construction of ULTIMA Hooklift
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
67
8
9

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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

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2.2 Main 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

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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. 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
8Preinstalled
in the factory
+24V
GND
5
4
9
10 11
12
(2)
13