MULTILIFT ULTIMA S User manual

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

Installation
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Installation
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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

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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

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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

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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

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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. Also check other possible protection needed for the electric and electronic systems. The
8-pin connector of the hooklift power supply on the I/O module must be detached before
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.
Before lifting the hooklift check the operation and condition of the lifting equipment, the lifting
hooks and wires, ropes or hoisting belts. Check the lifting capacity of the lifting equipment is
adequate to the weight of the hooklift and that lifting can be done safely. See 3.5 Lifting of
hooklift.

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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.
 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 chassis each time the vehicle is moved.

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3.3 Sub frame dimensions S & Z
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.
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
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, 59-61
ULT18S/Z 7.3331 14.6526 2.64 12.2196 -3.07 38.0368
ULT21S/Z
ULT24S, ULT26Z 9.7588 22.4813 2.87 14.8327 -3.62 64.6000
ULT26S
ULT30S 10.6144 26.1114 3.31 21.5104 -3.98 85.9036

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3.4 The sub frame dimensions SL & ZL
Hooklift type A subframe
(in2)
Wx top flange
(in3)
e top flange
(in)
Wx bottom fl.
(in3)
e bottom fl.
(in)
Ix
(in4)
ULT18 / 21SL 7.4323 17.6893 2.83 13.8176 -3.66 50.3950
ULT22 / 24 / 26SL
ULT20 / 24ZL 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 0.2433.31
ULT22 / 24 / 26SL
ULT20 / 24ZL 6.5 1.93 4.57 4.21 0.31 0.3133.46
The sub frame profile
material
EN10149 S355MC

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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. Check that the lifting hooks of lifting chains will fit
into the lifting lugs.
If the lifting lugs are not available, then the 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 operation of the lifting equip-
ment, hooks, ropes, wires and belts before lifting.
The weight of Ultima hooklifts can be seen in the table next page.
Remove the lifting lugs after the hooklift is lowered on the chassis.

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The weight of Ultima hooklift includes hydraulic locking but not the oil tank.
Hooklift type Weight (lbs)
ULT14S41 3527
ULT14S43 3593
ULT14S46 3660
ULT14S51 3880
ULT14S53 4056
ULT14S56 4101
ULT16S46 3836
ULT16S51 4056
ULT16S53 4233
ULT16S55/56 4277
ULT16S59 4387
ULT16S61 4431
ULT18S46 3902
ULT18S51 4123
ULT18S53 4321
ULT18S56 4409
ULT18S59 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
ULT18Z59 5556
ULT18Z61 5732
ULT21Z51 5930
ULT21Z53 5996
ULT21Z56 6107
ULT21Z59 6195
ULT21Z61 6261
ULT26Z51 5996
ULT26Z53 6063
ULT26Z56 6173
ULT26Z59 6261
ULT26Z61 6327
ULT26Z65 6504

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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)
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
ULT20ZL59 5930
ULT24ZL56 6019
ULT24ZL58 6129
ULT24ZL59 6129

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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.
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 oil
(max. 1 pt).
If the hooklift is equipped with preinstalled oil reservoir, the tank connector does not need to be
opened.
Ultima Base Ultima Flex & Pro

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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.
Flexible brackets, 2 - 4 pairs Fixed plates Rear plates
The predrilled holes in the truck chassis must be utilized, whenever possible.
The flexible brackets are installed to both sides of front cross member. The tightening torque of
the vertical M16 8.8 bolts is 22 ft-lb - ¼ 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 flexible brackets must be large plates or doubled
smaller plates. The large plates are necessary also under the middle frame / rear frame shaft.
When mounting the smaller plates the distance between the plates must be equal. The maxi-
mum distance of 43 ft must not be exceeded.
The rear beam is fastened to chassis with 6 x M14 (M16) fastening bolts on both sides.
Some truck manufacturers request M16 chassis fastener bolts (e.g. MB). Check the truck man-
ufacturer’s instructions.

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Examples of flexible brackets
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!
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