07 06 01 Installation Manual - UTK-2000 links DW-VZ.p65
Contents
1. Copyright by AHT 2006 20 u 1 FEED CYLINDER BEARING UTK 1000ST VZL 1 READY FOR WORK TOTAL WEIGHT 3364 OPTION with electrical hose burst valve HZ 750AL 42 MODEL UTK 1000ST AL TAILGATE SPECIFICATIONS with double acting feed cylinder for Liftarm L2750mm and Platform L 1500mm STANDARD SPECIFICATIONS 1000kg si 500mm Center FITTING REQUIREMENTS mm 1150 Max Height Unloaded 1040 Min Height Loaded 1370 Min Underbody Clearance Required OTHER SPECIFICATIONS 12 Installation Kit kg Aluminum Extrusion Profile 30mm thick PLATFORM Execution Arm Depth mm Arm Length mm Re Bushable Overall width mm Brocket Thickness mm uses Sete Codd 2 HYDRAULIC Power Pack Weather Proof Alum Enclosure Included and Sound Proof Motor Size 2 0kW All Aluminum Cylinder Quantity Two 2 Lift One 1 Feed Size 42mm max Stroke 222mm 250 930 max Stroke 480mm Quality Cylinder are all Aluminium Piston s Hard Chrome Plated Piston are all Ceramic plated and Rod Is Steel Teflon Sealed for Long Life Hose Burst Valve one mechanical Valve on each Lift Cylinder Leak Proof Check Valve Included Hoses 6mm 1 4 Thermo Plastic L2750mm 4pcs L2 550mm OPERATION Operation Tilting Operation automatical mechanical Tilting on the ground floor Closing Operation Battery Isolation Switch Integral to Power Pack Fixed Contral 4 Button on Power Pack Locking Device L2. FUSE BOX 11 INSTALLATION INSTRUCTIONS Correct wiring of the Power Pack NOTE All battery power leads must have a core area not less than 35mm at DC Motor 2 0kW and be double insulated Connect both battery cables and directly from the battery to the power pack ATTENTION By fixing the battery cable on the starter switch you must hold up the lock nut Battery Cable Lock Nut Starter Switch Energize the power pack and actuate each of the valves to be sure they are operating properly Please check the operating temperature regularly It should not increase by more than 20 C to 70 Check a new power pack for leakage after a short period of time Tighten any fittings that may be leaking 12 INSTALLATION INSTRUCTIONS Install the endstop cube Manually slide the tail lift out to the end of the rail Unfold the platform manually 1x time not complete e 5 Now raise the platform to the truck floor level by pressing the RAISE Button until the 2 lifting arms attach the truck Move in the complete tailgate unit with the help of a fork lift Clamp the mounting bracket with a screw clamp onto the rail Then lower the platform by pressing the LOWER Endstop Cube Sliding Bracket Cube must make a contact with sliding bracket Rail Weld the endstop cube on the upper and lower side onto the rail 13 adjusting screw 14 INSTAL
3. g Office Factory P gt Hauptplatz 23 BahnstraBe 34 2474 Gattendorf ALUHEBETECHNIK Tel 43 2142 64260 43 2142 64360 E Mail Gesellschaft mbH Fax 43 2142 6434 43 2142 64366 office oaht mhw com INSTALLER S MANUAL FOR THE AHT TAIL LIFT UTK 1000ST AL UTK 2000ST AL SS with double acting feed cylinder LEFT HAND DRIVER Gattendorf 2011 SERVICE QUALIFICATIONS TO INSTALL THE TAILGATE LOADER The installer should be well trained in the proper procedure for installing the AHT before beginning the installation Carefully read the manual before starting to install the AHT tailgate loader Only mature adults age 18 and above should install the AHT tailgate loader Installer should be well qualified for installing hydraulic equipment Installer should be well qualified for installing the electrical equipment INSTALLATION GUIDELINES 1 Remove bumpers lights tool box etc from rear of vehicle if necessary 2 Cut and shape the body and chassis to fit the tailgate 3 Install the rails onto the truck frame and check them with the checking device 4 Install the mounting brackets onto the rails 5 Position the tailgate unit under the truck Adjust the correct position and fix it 6 Energize the Power Pack 7 Raise the platform to truck floor level and fix the sliding brackets with screw clamps onto the rails 8 Weld the end stop cubes onto the rails 9 Move out the feed cylinder an
4. x 23 eoo db B LI E Uu S INSTALLATION INSTRUCTIONS Install the rails Before you can install the tailgate loader you have to mount the 2 rails onto the truck frame Pull outthe 2 rails from the sliding bracket ATTENTION THESLIDING ELEMENTS FROM THE SLIDING BRACKETS COME OUT Sliding Brackets Clamp the 2 rails with screw clamps onto the truck frame Position of the rails See next page The distance between rails and the end of the truck frame must be equal screw Clamps The 2 rails must be parallel The distance between truck frame and rails must be equal max 1mm INSTALLATION INSTRUCTIONS Install the rails Positionthe the rails as shown in the kinematic drawings Page 20 28 Place 1 checking device onto the rails as shown in the picture below CONTACT between rail and checking device Fasten the screw if the correct width is adjusted Check the width of the rails with 1 checking device on the front middle and rear If the difference between front middle and rear is 1mm you have to attach a sheet between rail and main frame max Tolerance 1 Check the width of the rails on the front middle and rear side INSTALLATION INSTRUCTIONS Install the rails Now place the second checking device onto the rail One on the front and the other on the rear of the rail If you looking behind from the truck the 2 checking devices must be parallel o
5. for Liftarm L 835mm and Platform L 1700mm CENTRE OF MASS FOR UTK 2000ST AL SS IN TRAVELING POSITION 1486 1250 578kg COMPLETE TAILGATE INCL POWERPACK 363 NN 16 02 2007 PAUL PFA t ATS Copyright by AHT 2006 DATENBLATTER LIW 28 HYDRAULIC SCHEMATIC for pump head PK UTK 2000 for double acting feed cylinder FEEDCYLINDER LIF TCYLINDER ARMY o 220bar i Lasa 4 I I u occ SE k u mu 29 NOILO3NNO2 oe 3SIVM 37872 TVHIdS TwNOILdO 034 7 419 9319 0 9 VSZ AZL 35713 3 5 ONNOYD J18vO NVA JiBvO NVA ELECTRIC SCHEMATIC with 2 Button Remote Control w F HOLIMS AH3Llva ZAH9 LWAL Q WAV439V10 ONIMIM 1IvOlsLO3 13
6. LATION INSTRUCTIONS How to adjust the mounting brackets Loosen the locking nut Adjust the easy movement of the mounting brackets by turning the adjusting screw ATTENTION The mounting brackets must move easily but they don t have any clearance Hold the adjusting screw and fasten the locking nut locking nut the locking nut INSTALLATION INSTRUCTIONS Install the cross beam feed cylinder Move outthe feed cylinder completely by pressing the OU T Button Then move in the feed cylinder for approximately 5 10mm Install a cross beam on the truck frame and screw on the feed cylinder bearing ATTENTION COVER THE PISTON ROD OF THE FEED CYLINDER BEFORE WELDING IT IS VERY IMPORTANT THAT THE FEED CYLINDER BE ABSOLUTELY PARALLEL WITH THE VEHICLE FRAME Cross beam Feed cylinder bearing Truck frame The pictures below show some problems that could happen if not installed properly NG WRONG 15 INSTALLATION INSTRUCTIONS Remove Tilting Lock The tilting lock prevents the automatic leveling from working until the installation is complete It is the last thing to remove MAIN FRAME TILTING BRACKET TILTING LOCK LIFT CYLINDER Remove the screw M6x25 on both sides Before removing the screw M6x25 the platform must be raised from ground SCREW M6x25 for TILTING LOCK TILTING BRACKET 16 FINISHING THE INSTALLATION How to adj
7. UMINUM 7200x1700 UTK 20WST SS 3AR 8306 2 suomGBRAKET UTK 2000ST SS tLI 604 s 15T HIS Ot PARTS UTK 20005T SS 5 506 s ATK RNST SS 6 454 gt uvRawM 057557 80 s 2 onpa 924 z ING BRACKET 200057 55 908 874 2 159 n 2 8 z 1 ree BEARNG 05i u i w 2 UFT CYLINDER 960 vith mech hose burst valve HZ P000AL 60M Bag s 1 FEED CYLINDER Double Acting MHW UTR 20005T 55 12 560 16 1 SLIDING BRACKET FOR POWER PACK ATK 20005T 14 1 FEED CYLINDER BEARING UTK 2000ST S5 VZL 1 _ 8 kq READY FOR WORK TOTAL WEIGHT 578kg OPTION with electrical hose burst valve HZ 2000AL 60E MODEL UTK 2000ST AL SS TAILGATE SPECIFICATIONS with double acting feed cylinder for Liftarm L2835mm and Platform L 1700mm STANDARD SPECIFICATIONS 2000kg at T000mm Gravly Center FITTING REQUIREMENTS mm 1435 Max Height Unloaded 1100 Min Height Loaded 1490 Min Underbody Clearance Required OTHER SPECIFICATIONS 15 Installation Kit kg Aluminum Extrusion Profile 40mm 35mm thick PLATFORM Execution Arm Depth mm 180mm x 180mm x 8 Lees sed Rss Ses Ten Cod
8. d S HYDRAULIC Power Pack Weather Proof Alum Enclosure Included and Sound Proof Motor Size 2 0kW All Aluminum Cylinder Quantity Two 2 Lift One 1 Feed Size 260mm max Stroke 310mm 250 930 max Stroke 700mm Quality Cylinder are all Aluminium Piston s Hard Chrome Plated Piston are all Ceramic plated and Rod Is Steel Teflon Sealed for Long Life Hose Burst Valve one mechanical Valve on each Lift Cylinder Leak Proof Check Valve Included Hoses 6mm 1 4 Thermo Plastic 2 L2750mm 5pcs L2 550mm OPERATION Operation Tilting Operation automatical mechanical Tilting on the ground floor Closing Operation amp Subject to Vehicle Type amp Floor Height 26 07 2007 PAUL ATE Copyright by AHT 2006 ke DATENELATTER LEW MODEL UTK 2000ST AL SS TAILGATE KINEMATICS for Liffarm L 835mm and Platform L 1 00mm MINIMUM MEASUREMENTS WORKING POSITION 1100 MIMIMUM MINIMUM MEASUREMENTS TRANSPORT POSITION 30 07 2007 PAUL be ATS Copyright by AHT 2006 26 MODEL UTK 2000ST AL SS TAILGATE KINEMATICS for Liftarm L 835mm and Platform L 1700mm MAXIMUM MEASUREMENTS WORKING POSITION 1538 s 1290 MAXIMUM MAXIMUM MEASUREMENTS TRANSPORT POSITION 30 07 2007 PAUL te TS k DATEMERATTER Liew Copyright by AHT 2006 27 MODEL UTK 2000ST AL S TAILGATE KINEMATICS uqyana
9. d install the cross beam with the feed cylinder bearing 10 Remove the tilting lock 11 Agjust the platform level 12 Install the warning flags 13 Finish the installation Mount lights spare tire etc UNPACKING THE TAILGATE LOADER A complete unit consisting of Main frame with lifting arms cylinders platform power pack sliding brackets rail 2 button remote control and installation manual Platform Sliding Bracket Main Frame NS Power Pack The tailgate loader is completely assembled tested and ready for use PREPARING FOR INSTALLATION Remove rear lights bumper tool box and spare wheel if necessary Disconnect the battery cable to prevent damage to the battery while working on truck body m c Subframe Tie down CSS J Remove any obstruction attached to the of the vehicle that would interfere with the installation The rail will cover the truck mainframe Rail The measurement of dimension A and B must be the same If Ais 1mm in difference of B you have to attach a sheet between rail and main frame max Tolerance 1mm Cutting and shaping body and chassis to fit the UTK Cut out the rear of the frame if necessary as shown in the installation drawings Reinforce the cut outs UTK 1000 130 1050 UTK 1000 130 UTK 1000 oo UTK 2000 175 1070 UTK 2000 175 UTK 2000
10. lves are adjustable from 50 250bar 700 3600PSI Adjustment of the relief valve a To adjust pressure a calibrated pressure gauge is required and it should be connected at the test point plug 8 NOTE 1bar equals 14 5PSI b Remove the seal and cover from the adjusting nut c Turn the adjusting screw with a hex wrench clockwise for higher pressure or counter clockwise for lower pressure sure to keep eye on the pressure gauge The maximum pressure should be 220bar 3190 5 d When pressure is correct lock the cap screw and check the pressure again to be sure it has not changed Seal the cover Caution Never bottom the relief valve The power pack and or hydraulic system could be damaged 6 Turn the main switch off 18 FINISHING THE INSTALLATION How to adjust the Flow Control Valve Adjustable flow control valve The Lifting speed is not adjustable The In and Out speed is not adjustable The lowering speed 15 adjusted by position 7 How to adjust the flow control valve Besurethe adjustable flow control valves are not closed regulate the lowering speed first carefully loose the M4 lock nut at the adjustable throttle Turn the cap nut to the right to lower the speed and turn the cap nut to the left to increase the speed Turn the screw one quarter turn at a time until the desired speed is reached When the desired speed is reached hold the cap
11. m UN Distance must be equal WRONG The 2 checking devices are not parallel gt The 2 rails are not parallel See Page 5 NOT PARALLEL If all dimension are OK and the 2 rails are parallel drill holes 16 in the truck frame 12 per rail 12 holes 016 rail Drill 2 holes in the truck frame put a bolt in each one and secure Then drill all other holes NUMBER OF SCREWS PER RAIL 12 pieces M16x50 THEN REMOVE ALL SCREW CLAMPS INSTALLATION INSTRUCTIONS Install the mounting brackets Loosen the 4 screws per mounting bracket and remove the mounting brackets from the main frame Loosen the 4 screws per mounting bracket Remove the 2 mounting brackets Move the mounting brackets onto the rails ATTENTION ALLSLIDING ELEMENTS MUST PLACE IN THE SLIDING BRACKETS 6 SLIDING ELEMENTS PER SLIDING INSTALLATION INSTRUCTIONS Install the mounting brackets ATTENTION The Angle between mounting bracket and cross bar must be 90 You can adjust the angle with the 2 adjusting nuts on the inner side of cross bar If the Angle is correct you have to lock the 2 cross bars with the locking nut OOO Locking nut Adjusting nut Locking nut The mounting brackets must move easily with hand INSTALLATION INSTRUCTIONS Position the Tailgate Place the tailgate with a fork lift under the truck The mainframe of the tailgate must be unde
12. nut and tighten the M4 lock nut max 1 5Nm e The lowering speed should be as follows Maximum lowering speed should be 6 150mm per second Maximum lowering speed is 40 in 7 seconds 1 7 seconds Mount the warning flags with 3 rivets on each flag Finishing the Installation Lubricate all grease fittings Check all Locking brackets Check the oil level Check all hydraulic hoses and cylinders for tightness 19 MODEL UTK 1000ST AL BASIC DIMENSIONS with double acting feed cylinder for Liffarm L2 750mm and Platform L 1500mm 1 i cross Seam Ta 1 PATFORHALUMNUM 2200x1500 a SuONG BRACKET 904 s ATKCISIS AL uvam 1004 s DONT PLATE AW usrsR 35 3 muting BRACKET Amr m tss m 2 1854 Feeo CYUNDER BEARING us vz 2000 osko 8 POWERPACK w 1 UFT CYUNDER 662 mech burst valve WI ISMAL AIM 60g 5 FEED CYLNDER Double Acting owsuwem 399 1 1 SIDING BRACKET FOR POWER PACK a 480 STROKE UM 900 FRAME WIDTH 690 MIN FRAME WIDTH
13. ock between Truck Frame and folded Platform Removable Remote Push Button 2 Button Hand Held c w 3m Lead Yes Flush Mounted Subject to Vehicle Type amp Floor Height Copyright by AHT 2006 21 MODEL UTK 1000ST AL TAILGATE KINEMATICS for Lifrarm L2 750mm and Platform L 1500mm MINIMUM MEASUREMENTS WORKING POSITION 1410 MAXIMUM 0 1040 MINIMUM MINIMUM MEASUREMENTS TRANSPORT POSITION 140 MINIMUM 1000 STROKE 480 ij 1040 MINIMUM Copyright by AHT 2006 22 MODEL UTK 1000ST AL TAILGATE KINEMATICS for Lifrarm L2 750mm and Platform L 1500mm MAXIMUM MEASUREMENTS WORKING POSITION a STROKE 480 BELADUNG 1000kg LOAD uwawan So 150 MAXIMUM ku EL D w MAXIMUM MEASUREMENTS TRANSPORT POSITION 1370 MINIMM Er ER RES E m N Copyright by 2006 23 MODEL UTK 2000ST AL SS with double acting feed cylinder gt E L ii Copyright by AHT 2006 24 44 BASIC DIMENSIONS for Liffarm L 835mm and Platform L 1 00mm i PART PCS DESCRIPTION 1 X CROSS BEAM UTK 2MUST SS IVI MT DSU _ T 3kg 2 r urram 7104 3 PLATFORM AL
14. r the mounting brackets The tailgate must be centric to the truck Raise the complete tailgate with a fork lift to the correct position and install the mounting brackets onto the main frame Don t fasten the 4 Screws per mounting bracket complete ATTENTION THEANGLE BETWEEN MOUNTING BRACKET AND MAIN FRAME MUST BE 90 THE POSITION OF THE MAIN FRAME MUST BE CENTRIC TO THE TRUCK If the tailgate is in the correct position fasten all screws at the mounting brackets 4 per mounting NE bracket 4 screws per mounting bracket 10 INSTALLATION INSTRUCTIONS Energize the power pack CAUTION REMOVE TRANSPORT FILLER CAP AND INSERT DIPSTICK There is no air hole in filler cap and the pump or reservoir will be destroyed Be sure the vehicle and the liftgate are ofthe same voltage 12V or 24V Fuse is in the power pack 12V 25 Amp and 24V 16 Amp Connect the positive cable directly from the battery to the starter solenoid Connect the negative cable directly from the battery to the motor ground Complete all other electrical work Connect all control switches CAUTION REMOVE TRANSPORT FILLER CAP AND INSERT DIPSTICK There is no air hole in transport filler cap and the pump or reservoir will be destroyed ll T u T y Batterie cable Build in between Battery and Cable the Main Fuse MAIN FUSE 12V 2 125 Ampere 24V 80 Ampere 2
15. ust the platform level 1 the platform completely 2 Loosen the locking nut on both sides Locking nut Screw to adjust the platform level Adjust the platform Turn out the screw for raise the platform tip Turn out the screw for raise the platform tip Turn in the screw for lower the platform tip Turn in the screw for lower the platform tip no contact contact 3 If the platform level is correct fasten the locking nut on both sides 17 FINISHING THE INSTALLATION How to adjust the maximum Lifting Pressure 1 Turn on the Main Switch 2 Openthe platform and lower to the ground 3 Lower the platform tip to the ground 4 Load the platform with the maximum rated load and one person Be sure to place the load in the center of platform and at 1000mm from the vehicle Check the vehicle data plate 5 Press the Raise Button If the platform does not raise the relief valve is set too low MAX LOADING How to adjust the relief valve The relief valves are sealed at the factory The seals must not be removed unless authorized by the factory Warranty is void if seal is broken There are 2 different places to adjust the hydraulic pressure Relief Valve is to adjust the LIFTING pressure Factory setting is 220bar 3190PSl Relief Valve 3B is to adjust the SLIDE IN and SLIDE OUT pressure Factory setting is 100bar 1450PSl All 2 relief va
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