Palfinger PTC 750 S Assembly Instructions Manual
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Palfinger PTC 750 S Assembly Instructions Manual

Palfinger PTC 750 S Assembly Instructions Manual

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PALFINGER TAIL LIFTS
ASSEMBLY INSTRUCTIONS
TAIL LIFTS
STANDARD

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Summary of Contents for Palfinger PTC 750 S

  • Page 1 PALFINGER TAIL LIFTS ASSEMBLY INSTRUCTIONS TAIL LIFTS STANDARD...
  • Page 3 Assembly instructions PALFINGER Tail Lifts Tail Lift Standard 07-500.99-04.10-03 13.09.2019 Ref. no.: 2032342 A 23591...

  • Page 4: Table Of Contents

    Table of contents Table of contents About these instructions ..........6 Abbreviations used ..............6 Enclosed documents ..............6 Important safety information ........8 Personnel qualifications ............8 Warning notices in these assembly instructions ....... 9 You must take these points into account during assembly ..10 Required tools and auxiliary equipment ....
  • Page 5 Table of contents Adjusting and testing installed tail lift ....... 50 10.1 Set tilt switch b13 ..............50 10.2 Air bleeding the hydraulic cylinders ........51 10.3 Checking horizontal position on ground ......... 51 10.4 Performing an oil level check ..........52 10.5 Checking screw connections ..........

  • Page 6: About These Instructions

    About these instructions About these instructions These assembly instructions contain important information to ensure that the PALFINGER Tail Lifts tail lift is safely and properly installed.  Read these assembly instructions all the way through, particularly the chapter "Important safety information" on page 8, before attaching the tail lift.
  • Page 7 About these instructions • Brief operating instructions • Type plate • Attachment report (attachment diagram) • General installation drawing...

  • Page 8: Important Safety Information

    Important safety information Important safety information The PALFINGER Tail Lifts tail lift has been built according to the state-of-the-art and to recognised safety engineering rules. Never- theless there is a danger of personal injury and material damage if you do not comply with the instructions in this chapter and in this op- erating manual.

  • Page 9: Warning Notices In These Assembly Instructions

    Indicates possible material damage. The environment, ATTENTION! equipment or the PALFINGER Tail Lifts tail lift may be damaged if you fail to avoid this danger. If you do not observe this information, the assembly process NOTE may be adversely affected.

  • Page 10: You Must Take These Points Into Account During Assembly

    Tail Lifts contract workshops. Your nearest contract workshop and other contact information can be found in the workshop directory. • Only use PALFINGER Tail Lifts original parts during assembly work. • Observe all applicable accident prevention regulations. • Observe the vehicle manufacturer's attachment guidelines.
  • Page 11 • Make sure that the PALFINGER Tail Lifts tail lift and its moving parts, the coupling, the brake system, the oil lines, the pneumatic lines and the cabling of the vehicle are not damaged.

  • Page 12: Required Tools And Auxiliary Equipment

    Required tools and auxiliary equipment Required tools and auxiliary equipment To assemble your PALFINGER Tail Lifts tail lift you will need the following tools and auxiliary equipment: Tools Wrench size in mm: 6, 8, 10, 13, 32, 36, 41, 46, 50, 60, 65, 70...

  • Page 13: List Of Models And Scope Of Delivery

    List of models and scope of delivery List of models and scope of delivery Below a list of standard version models of PALFINGER Tail Lifts tail lifts. The following models are available: MBB C 1000 S – C 3000 S MBB C 1000 LD –...

  • Page 14: Standard Tail Lift

    List of models and scope of delivery Standard tail lift Attachment grab handle (not Warning lamps (option) included in scope of delivery) Startup rail (roll bar, option) Side control panel (option) Useful load centre of gravity Hydraulic unit and controller Platform Underride protection Torsion frame...

  • Page 15: Tail Lift With Welded Consoles And Slide-In Unit

    List of models and scope of delivery Tail lift with welded consoles and slide-in unit Welded console plates Tilt cylinder Hydraulic unit Lift cylinder Underride protection Lift rocker Tail lift with bolted consoles and slide-in unit Bolted console plates Tilt cylinder Hydraulic unit Lift cylinder Underride protection...

  • Page 16: Tail Lift With Platform And Turning Unit

    Bolted console plates Tilt cylinder Hydraulic unit Lift cylinder Underride protection Platform Turning unit Scope of delivery The scope of delivery of your PALFINGER Tail Lifts tail lift is based by the model you ordered and any agreed special accessories.

  • Page 17: Preparing For Installation

     First read this assembly manual through and then follow the instructions step-by-step.  You should also observe the operating manual for your PALFINGER Tail Lifts tail lift and in particular all the safety instructions.  Perform all the preparatory work properly and carefully.
  • Page 18 When all these points have been checked off, you can start with the installation of your PALFINGER Tail Lifts tail lift. The installation consists of several steps, which are described in more detail on the following pages. They include: •...

  • Page 19: Preparing Vehicle

    Preparing vehicle Preparing vehicle Before mounting the PALFINGER Tail Lifts tail lift on your vehicle, you must prepare the vehicle accordingly. The specific steps vary according to the intended purpose and the vehicle type. You can obtain the most important technical parameters from...

  • Page 20: Removing Projecting Parts Of The Vehicle

    • parts of the vehicle exhaust.  Store the removed components in a secure, dry place. Components that are not compatible with your PALFINGER Tail Lifts tail lift may not be reinstalled.  Consult your vehicle maker to find alternative solutions for...

  • Page 21: Creating Cutouts For The Lifting Mechanism (Optional)

    PALFINGER Tail Lifts tail lift. Your vehicle's rear cross-member should be able to bear approximately twice the rated load of your PALFINGER Tail Lifts tail lift (e.g. with a 1000K tail lift around 2000 kg). If the rated load of the rear cross-member is insufficient for the ordered PALFINGER Tail Lifts tail lift, you may have to reinforce it.

  • Page 22: Preparing Vehicles With Box Bodies

    Preparing vehicle Preparing vehicles with box bodies A sealing system can be ordered from PALFINGER Tail Lifts and Mounting the sealing system pre-installed for vehicles with box bodies. The sealing system is mounted according to the special assembly instructions supplied.

  • Page 23: Installing Lifting Mechanism

    Installing lifting mechanism Installing lifting mechanism There are two options for mounting the lifting mechanism: • Installation with installation aids (see chapter 7.1 on page 23) • Installation with mounted platform (see chapter 7.2 on page 32) Installation with installation aids To assist in the installation of the lifting mechanism of your PALFIN- GER Tail Lifts tail lift, you can on request obtain special installation aids.
  • Page 24 Installing lifting mechanism  Lay the installation aids on the loading area.  Align the installation aids on the loading area. Refer to the dimensions in the general assembly diagram.  Securely fix the installation aids to the vehicle chassis with, for example, screw clamps.
  • Page 25 Installing lifting mechanism 7.1.3 Bolting the lifting mechanism to the installation aid  Make sure that the lifting mechanism is in its final installation position.  It may be necessary, for example if a sealing system is present, to attach spacers to ensure correct spacing between the control rod and vehicle chassis.
  • Page 26 The installation sequence differs according to the type of console plates used. The welded consoles are attached in advance by PALFINGER Tail Lifts to the lifting mechanism. The customer notifies PALFINGER Tail Lifts of the required distances between the consoles and these cannot be subsequently changed.
  • Page 27 Installing lifting mechanism To fix the lifting mechanism with welded consoles to the vehicle chassis, proceed as follows:  Mark the following holes on the console plate. Observe the general assembly diagram and vehicle manufacturer's box body mounting guidelines. Above all, note the number, position and diameter of drill holes.
  • Page 28 Installing lifting mechanism Table 1: Tightening torques on the consoles Tightening Type of tail lift Bolts/consoles Bolt type torque C 500 SD C 500 SPLD/SPRD C 750 SPL/SPR C 750 S C 500 LD M14x1.5 190 Nm C 750 L C 750 LX C 750 LG C 750 LD...
  • Page 29 Installing lifting mechanism To fix the lifting mechanism with bolted consoles to the vehicle chassis, proceed as follows: NOTE We recommend installation of the bolted consoles to the vehicle chassis before positioning of the lifting mechanism under the vehicle. optional stand tube hex.
  • Page 30 Installing lifting mechanism  Mount the lifting mechanism as described in section “Installing lifting mechanism” frompage 23.  Then precisely align the console plates (2) with respect to height and width to the chassis.  Fix the console plates to the vehicle chassis and tighten the hex. nuts (5).
  • Page 31 • Box unit • Universal unit The hydraulic unit is normally premounted by PALFINGER Tail Lifts. On request, you can also obtain a box unit with long cables and hoses. You can then mount this box unit at any position under the vehicle.

  • Page 32: Installation With Attached Platform

    Installing lifting mechanism Installation with attached platform The following steps are required when installing with premounted platform: • position lifting mechanism under the vehicle (see chapter 7.2.1 on page 32), • mount the platform on the lifting mechanism (see chapter 7.2.2 on page 33), •...
  • Page 33 Installing lifting mechanism 7.2.2 Mounting the platform on the lifting mechanism  Mount the platform on the lifting mechanism.  Bolt the platform to the control rod without the tilt cylinders. Use the spacer discs supplied to align the platform with the body. 7.2.3 Mounting auxiliary device CAUTION...
  • Page 34 Installing lifting mechanism  Align the auxiliary device to the load area and fix it securely to the vehicle chassis with, for example, screw clamps.  Ensure that the auxiliary device at least correspondingly projects above the platform height at the back. 7.2.4 Positioning and fixing the platform ...
  • Page 35 Installing lifting mechanism 7.2.5 Installing lifting mechanism  Proceed with the installation of the lifting mechanism from step “Positioning the stand tube” on page 26.  Fix the lifting mechanism according to the type of console plates used (see chapter 7.1.5 on page 26).

  • Page 36: Establishing Electrical Connections

    Establishing electrical connections Establishing electrical connections To electrically connect your tail lift, use the supplied PALFINGER Tail Lifts electrical circuit diagram and the vehicle maker's attach- ment guidelines. You will find the respective PALFINGER Tail Lifts electrical circuit diagram in the electrical unit on the circuit board.
  • Page 37 Establishing electrical connections Optional:  Run the ground cable to the battery. Shorten as required.  Crimp the cable lug and mount it on the battery's minus terminal. With vehicles with preinstalled ETMA interface  Plug the plus and minus cables into the mating plugs. NOTE With hazardous goods vehicles, the ground cable must be connected to the battery or in accordance with the respective vehicle manufacturer's guidelines for mounting...

  • Page 38: Installing And Connecting The Control Unit

    The optional control unit must be mounted in a suitable location in the driver's cab. If a control unit is already present in the vehicle, you must connect your PALFINGER Tail Lifts tail lift according to a special circuit di- agram, which you can obtain from PALFINGER Tail Lifts. NOTE Connection of the control device must not take place until the electrical connection of the plus and minus cable has taken place.

  • Page 39: Connecting The Manual Cable Switch/Remote Control (Optional)

     Mount the socket.  Connect the cable from the manual cable switch in the terminal box in accordance with the PALFINGER Tail Lifts circuit diagram.  Find a suitable and secure storage location for the manual cable switch. Operation of the manual cable switch only permissible...
  • Page 40 The manual cable switch is then fixed and cannot be unplugged. The required circuit diagram is available on request from PALFINGER Tail Lifts. The receiver for a wireless remote control is prewired and only has...

  • Page 41: Installing And Connecting The Platform

    Installing and connecting the platform Installing and connecting the platform If you have assembled your PALFINGER Tail Lifts tail lift with pre- mounted platform (see chapter 7.2 onpage 32), you can skip the first three steps in the platform assembly instructions and begin with step “Adjusting the tilt cylinder”...

  • Page 42: Bolting The Platform To The Control Rod

    Installing and connecting the platform  Carefully raise the platform and move it into the installation position at the truck tailgate.  Maintain the installation position with the lifting equipment until the platform is bolted to control rod and tilt cylinders. Bolting the platform to the control rod ...
  • Page 43 Installing and connecting the platform  Push the bolt through completely.  Put the lug on the bolt. Use a hammer to knock in the lug as far as it will go. Turn the lug to the screw-on position.  Screw on the lug with the M12 screw. ...

  • Page 44: Bolting The Platform To The First Tilt Cylinder

    Installing and connecting the platform Bolting the platform to the first tilt cylinder Depending on your tail lift model, you will need to bolt one or two tilt cylinders to the platform. If your tail lift is equipped with two tilt cyl- inders, you should initially only bolt one tilt cylinder to the platform.
  • Page 45 Installing and connecting the platform  Slide the hydraulic unit back in, close the sealing cap and secure this with the clip.  Then check whether the hydraulic unit is correctly connected. Refer to the enclosed hydraulic circuit plan. Bolting the platform to the tilt cylinder ...
  • Page 46 Installing and connecting the platform  Bolt the tilt cylinder to the platform. Use the spacer discs supplied to align the cylinder with the control rod.  Push the bolt through completely.  Put the lug on the bolt. Use a hammer to knock in the lug as far as it will go.

  • Page 47: Adjusting The Tilt Cylinder

     Release the tilt cylinder by opening the platform.  Tighten the locking nut on the piston rod as per the PALFINGER Tail Lifts assembly diagram.  Pull the bellows back over the piston rod and secure it with the...

  • Page 48: Bolting The Platform To The Second Tilt Cylinder

    Installing and connecting the platform Bolting the platform to the second tilt cylinder (apart from the types DUO and 1000 E) If you have bolted the platform to the first tilt cylinder, you can now bolt it to the second tilt cylinder. The second tilt cylinder is installed as described in chapter 9.3 on page 44.

  • Page 49: Installing Tilt Sensors

    Installing and connecting the platform Installing tilt sensors A tilt sensor b15 is shown in the image. The tilt sensor b16 is also mounted with the cable downwards. Proceed as follows for b15 and b16:  Mount the tilt sensors as shown on the right of the platform. ...

  • Page 50: Adjusting And Testing Installed Tail Lift

    Adjusting and testing installed tail lift Adjusting and testing installed tail lift When you have installed your PALFINGER Tail Lifts tail lift, you must then adjust it and test that it is functioning properly. This entails the following jobs: • adjust the tilt switch b13 (see chapter 10.1 on page 50) •...

  • Page 51: Air Bleeding The Hydraulic Cylinders

    Adjusting and testing installed tail lift 10.2 Air bleeding the hydraulic cylinders  Raise and lower the platform several times.  Open and close the platform several times. 10.3 Checking horizontal position on ground NOTE This test only has to be performed if tilt switch b16 is provided. ...

  • Page 52: Performing An Oil Level Check

    Adjusting and testing installed tail lift 10.4 Performing an oil level check A slide-in unit is shown in the image. The oil level check is per- formed in a similar way for turning, box and universal units. Slide-in unit To check the oil level: ...

  • Page 53: Checking Screw Connections

    Adjusting and testing installed tail lift 10.5 Checking screw connections  Study the PALFINGER Tail Lifts assembly diagram.  Obtain the required tightening torques for the screw connections from the PALFINGER Tail Lifts assembly drawing.  Make sure that all screw connections are secure.

  • Page 54: Attaching Warning Strips And Type Plate

    Adjusting and testing installed tail lift 10.6 Attaching warning strips and type plate The scope of delivery of all PALFINGER Tail Lifts tail lifts includes two warning strips. The warning strips are mounted according to the enclosed "Assembly instructions for warning strips" (drawing no.
  • Page 55 Adjusting and testing installed tail lift  To decrease the contact pressure of the props, turn the grub screw anti-clockwise one rotation.  To increase the contact pressure of the props, turn the grub screw clockwise one rotation.  After adjusting the contact pressure, check the adjustment by lowering the props.

  • Page 56: Performing Acceptance Test As Per Test Book

    Adjusting and testing installed tail lift 10.8 Performing acceptance test as per test book  Perform initial commissioning in accordance with the test book.  Enter the required details in the test book. • Company • Code • Installation company •...

  • Page 57: 11 Index

    Index 11 Index Abbreviations 6 Adjusting tail lift the tilt cylinder auxiliary equipment 12 Bolting platform to the control rod platform to the tilt cylinders the platform to the tilt cylinder Enclosed documents 6 Foot-operated switch Connecting plug Hydraulic circuit diagrams 59 Installing control unit tilt sensors...
  • Page 58 Index Tail lift platform standard with bolted consoles with welded consoles Tools 12 Truck with box body Warnings Layout...

  • Page 59: 12 Hydraulic Circuit Diagrams

    Hydraulic circuit diagrams 12 Hydraulic circuit diagrams 12.1 Standard tail lift with four cylinders 96-560.98-00.00-00 TILT LIFT LIFT TILT CYLINDER CYLINDER CYLINDER CYLINDER DBV1...
  • Page 60 Hydraulic circuit diagrams 12.2 Standard Tail Lift With Soft Levelling KIPPZYL.
  • Page 61 Hydraulic circuit diagrams 12.3 Standard tail lift with two cylinders 97-510.98-00.00-00 TILT LIFT CYLINDER CYLINDER DBV1...
  • Page 62 Hydraulic circuit diagrams 12.4 Standard tail lift with hydraulic support 96-524.98-01.00-00 TILT LIFT LIFT TILT CYLINDER CYLINDER CYLINDER CYLINDER < DBV1...
  • Page 63 Hydraulic circuit diagrams 12.5 Tail lifts with hydraulic support MBB C 750 L C 1000 L –...
  • Page 64 Hydraulic circuit diagrams 12.6 Standard tail lift with hydraulic under-ride protection 99-514.98-01.00-00/3 TILT LIFT LIFT TILT CYLINDER CYLINDER CYLINDER CYLINDER...
  • Page 66 PALFINGER Tail Lifts GmbH Fockestraße 53 D-27777 Ganderkesee/Hoykenkamp Tel.: +49-4221 8530 Fax: +49-4221 87536 infombb@palfinger.com www.palfinger.com PALFINGER Hayons S.A.S Rue de l‘Eglise F-61310 Silly en Gouffern Tel.: +33-2 33 12 44 00 Fax: +33-2 33 12 44 01 francembb@palfinger.com www.palfinger.com PALFINGER Tail Lifts s.r.o.

This manual is also suitable for:

Mbb c 3000 sMbb c 1000 lPtc 1000 llwMbb c 750 lMbb c 750 sMbb c 750 slw ... Show all

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