Palfinger C 1000 S Assembly Instructions Manual
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Palfinger C 1000 S Assembly Instructions Manual

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PALFINGER TAIL LIFTS
ASSEMBLY
INSTRUCTIONS
STANDARD TAIL LIFTS
LIFETIME EXCELLENCE

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Summary of Contents for Palfinger C 1000 S

  • Page 1 PALFINGER TAIL LIFTS ASSEMBLY INSTRUCTIONS STANDARD TAIL LIFTS LIFETIME EXCELLENCE...
  • Page 3 Assembly instructions PALFINGER Tail Lifts Standard tail lifts Dok: 07-500.99-04.10-03 Date: 19.06.2023 SNr: 2032342 Index: A25103...

  • Page 4: Table Of Contents

    Table of contents About these assembly instructions ..........7 1.1. Abbreviations used ..............7 1.2. Scope of delivery ..............7 1.3. Enclosed documents ............... 8 Important safety information............. 9 2.1. Personnel qualifications ............9 2.2. Warning notices in these assembly instructions ..... 10 2.3.
  • Page 5 Installing the lifting mechanism ............. 27 7.1. Pre-assembling the lifting mechanism ........29 7.1.1. Tail lifts PTC 750 L - 1000 LLW ........29 7.1.2. Tail lifts with laterally adjustable bolted consoles ..30 7.2. Attachment of the lifting mechanism to the vehicle ....33 7.2.1.
  • Page 6 10. Adjusting and testing installed tail lift ..........63 10.1. Setting tilt sensor B15 ............63 10.2. Adjusting tilt sensor B15S ............64 10.3. Setting tilt switch B13 ............66 10.4. Bleeding the hydraulic cylinders ..........67 10.5. Bleeding the hydraulic cylinder (G < 450 mm) ....... 68 10.6.

  • Page 7: About These Assembly Instructions

    1.1. Abbreviations used Abbreviation/symbol Meaning ETMA European Taillift Manufacturers Association 1.2. Scope of delivery The scope of delivery of your PALFINGER Tail Lifts tail lift is based on the model you ordered and any agreed special accessories.

  • Page 8: Enclosed Documents

    ► Observed all documents enclosed with your ordered PALFINGER Tail Lifts tail lift. ► In addition, you should also observe the operating instructions for the PALFINGER Tail Lifts tail lift and all documents from the vehicle manufacturer. The following documents are enclosed with the PALFINGER Tail Lifts tail lift: •...

  • Page 9: 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. Nevertheless there is a danger of personal injury and material damage if you do not comply with the following general safety instructions and the warnings in these assembly instructions.

  • Page 10: Warning Notices In These Assembly Instructions

    2.2. Warning notices in these assembly instructions In these assembly instructions safety instructions precede a procedure which incurs risks of personal injury or material damage. Warnings are structured as follows: SIGNAL WORD! Description of type and source of the danger! Description of consequences of non-observance.

  • Page 11: You Must Take These Points Into Account During Assembly

    PALFINGER Tail Lifts contract workshops. You can find your nearest authorised workshop in the location search at www.palfinger.com under “ales and service search”. ► Only use PALFINGER Tail Lifts original parts during assembly work. ► Observe all applicable accident prevention regulations. ► Observe the vehicle manufacturer's attachment guidelines.

  • Page 12: During Assembly

    ► When connecting the hydraulic parts, ensure that the connections are clean and that no contamination can get into the hydraulic circuit. ► 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 13: 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, 15, 17, 19, 21, 36, 41, 46, 50, 60, 65, 70...

  • Page 14: Model Line

    Model line Below a list of standard version models of PALFINGER Tail Lifts tail lifts. The following models are available: C 1000 S – C 3000 S C 1000 LD – C 2500 L C 1500 SZ – C 2500 SZ C 1500 SK –...

  • Page 15: Standard Tail Lift, Overview

    4.1. Standard tail lift, overview Figure 1: Standard tail lift, overview 1 Operating unit (Slimpanel) 6 Tilt cylinder 2 Stand tube 7 Torsion frame, control rod 3 Hydraulic unit and controller 8 Lift cylinder (in stand tube) 4 Hydraulic prop 9 Platform 5 Underrun protection...

  • Page 16: Tail Lift With Welded Consoles And Slide-In Unit

    4.2. Tail lift with welded consoles and slide-in unit Figure 2: Tail lift with welded consoles and slide-in unit 1 Welded console plates 4 Tilt cylinder 2 Stand tube 5 Lift cylinder 3 Underrun protection 6 Torsion frame...

  • Page 17: Tail Lift With Bolted Consoles And Slide-In Unit

    4.3. Tail lift with bolted consoles and slide-in unit Figure 3: Tail lift with bolted consoles and slide-in unit 1 Bolted console plates 4 Tilt cylinder 2 Hydraulic unit (in stand tube) 5 Lift cylinder 3 Underrun protection 6 Torsion frame...

  • Page 18: Tail Lift With Platform And Turning Unit

    4.4. Tail lift with platform and turning unit Figure 4: Tail lift with platform and turning unit 1 Platform 4 Underrun protection 2 Turning unit 5 Tilt cylinder 3 Bolted console plates 6 Lift cylinder...

  • Page 19: Tail Lift Without Torque Support

    4.5. Tail lift without torque support Figure 5: Tail lift without torque support 1 Platform 5 Linkage mount 2 Control rod, stroke 6 Underrun protection 3 Lift cylinder 7 Control rod, tilt 4 Universal unit 8 Tilt cylinder...

  • Page 20: Tail Lift With Torque Support

    4.6. Tail lift with torque support Figure 6: Tail lift with torque support 1 Platform 5 Linkage mount 2 Tilt cylinder 6 Underrun protection 3 Lift cylinder 7 Trailer hitch 4 Universal unit...

  • Page 21: Preparing For Assembly

    ► 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. ► If in doubt or if you have any questions, contact PALFINGER Tail Lifts before proceeding with work. CAUTION!
  • Page 22 When all these points have been checked off, you can start with the assembly or pre-assembly (for PTC 750 L - PTC 1000 LLW) of your PALFINGER Tail Lifts tail lift. Assembly consists of several steps, which are described in more detail on the following pages. They include: •...

  • Page 23: Preparing The Vehicle

    Preparing the 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. Technical parameters ► Determine the most important technical parameters for the attachment of your tail lift.

  • Page 24: Removing Projecting Parts Of The Vehicle

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

  • Page 25: Reinforcing Rear Cross-Member (Optional)

    Your truck's rear cross-member must be rated for your ordered type of PALFINGER Tail Lifts tail lift. The rear cross-member of your vehicle should be capable of carrying twice the load capacity of your PALFINGER Tail Lifts tail lift (e.g. about 2000 kg for a 1000K tail lift).
  • Page 26 ► Prepare the spacers for the lifting mechanism area (if necessary). ► Fix the spacers to the door. ► Create a bridging profile (e.g. a square tube with rounded edges 60x40x3). ► Mount the bridging profile over the entire loading area width.

  • Page 27: Installing The Lifting Mechanism

    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 console plates and these cannot be subsequently changed.
  • Page 28 Vehicle chassis Adapter Claws Figure 8: Attachment with adapters and clamping pieces (claws)

  • Page 29: Pre-Assembling The Lifting Mechanism

    7.1. Pre-assembling the lifting mechanism 7.1.1. Tail lifts PTC 750 L - 1000 LLW ► Fit the console plates to the linkage mounts with the M14 bolts provided. When doing so, observe the prescribed tightening torques (see table on page 31). ►...

  • Page 30: Tail Lifts With Laterally Adjustable Bolted Consoles

    7.1.2. Tail lifts with laterally adjustable bolted consoles Figure 10: Pre-assembly with laterally adjustable bolted consoles 1 Stand tube 5 hex. nuts 2 console plate 6 Console plate pocket 3 hooks 7 Safety clips 4 Press-in screws M20x1.5 8 ground cable (option) (pressed in when the tail lift is delivered) ►...
  • Page 31 Reinforcement of the bolted consoles on C 1000 S and C 1500 L On the C 1000 S and C 1500 L tail lifts, the console plates must be reinforced with the mounting kit (item no. 2030247) (see Figure 11, page 32).
  • Page 32 Figure 11: Reinforcement of the console plates 1 console plate 3 T-profile 2 Plate 4 Bolt/nut M10 ► Place the plates against the console plates on both sides and hook them behind the T-profiles (see Figure 11). ► Screw the plates to both console plates.

  • Page 33: Attachment Of The Lifting Mechanism To The Vehicle

    7.2. Attachment of the lifting mechanism to the vehicle To assist in the installation of the lifting mechanism of your PALFINGER Tail Lifts tail lift, you can on request obtain special installation aids (see Figure 12, page 33). This installation aids support you in mounting the lifting mechanism.

  • Page 34: Positioning Lifting Mechanism Under The Vehicle

    7.2.1. Positioning lifting mechanism under the vehicle ► Raise the lifting mechanism with suitable lifting equipment such as a forklift truck or with a pallet truck, for example. Note: We recommend lifting the lifting mechanism on the pallet on which it is delivered and positioning it under the vehicle.

  • Page 35: Positioning And Fixing The Installation Aids On The Vehicle Chassis

    7.2.2. Positioning and fixing the installation aids on the vehicle chassis CAUTION! Danger of injury! If you incorrectly position the installation aids or do not fix it correctly, the torsion frame may fall. Personal and material damage are possible. ► Make sure that the installation aids are correctly positioned and properly fixed.

  • Page 36: Bolting The Lifting Mechanism To The Installation Aid

    7.2.3. Bolting the lifting mechanism to the installation aid ► Make sure that the lifting mechanism is in its final installation position. ► With a sealing system, fit 25 mm spacers to ensure the correct distance between the torsion frame control rods and the vehicle chassis (see note on page 37).
  • Page 37 Note: When attaching a plastic-coated platform: ► Place 2 mm plates between the control rods of the torsion frame and the superstructure as spacers (see Figure 16). This is necessary because otherwise the platform will stand too high after assembly. When attaching a sealing system to the box body: ►...
  • Page 38 Figure 17: Check the central position of the lifting mechanism (1) Figure 18: Check the central position of the lifting mechanism (2)

  • Page 39: Positioning The Stand Tube / Linkage Mounts

    7.2.4. Positioning the stand tube / linkage mounts ► Position the stand tube / linkage mounts at a height according to the specified dimensions in the attachment report (dimensions "F", "G" and "H" in the attachment diagram, see Figure 19). Note: The dimensions "F", "G"...
  • Page 40 ► Console plate Vehicle chassis Subframe loading floor Stand tube Figure 20: Positioning the stand tube ► Check the lateral position of the lifting mechanism again.

  • Page 41: Fixing The Console Plates On The Vehicle Chassis

    7.2.5. Fixing the console plates on the vehicle chassis Determining the arrangement, number and size of the fixing holes Depending on the type of tail lift, the permitted payload and the presence of a ball head coupling, the attachment of the console plates to the vehicle is subject to different loads during operation.
  • Page 42 Number of bolts per Tightening Type of tail lift Bolt type console torque plate C 500 SD C 500 SPLD/SPRD C 750 SPL/SPR C 750 S C 500 LD C750 L M12x1.5 – St10.9 110 Nm M14x1.5 - St10.9 190 Nm C 750 LG C 750 LD C 1000 ML (PRO)
  • Page 43 Number of bolts per Tightening Type of tail lift Bolt type console torque plate C 1500 S C 1500 LX – C 2000 LX C 1500 SZ C 2000 LZ M14x1.5 - St10.9 190 Nm C 1500 SK – C 2500 SK C 2000 L –...
  • Page 44 Subframe loading floor Fittings Console plate Vehicle chassis Figure 21: Bolting console plates Drilling the holes, screwing the console plates to the vehicle frame ► Drill the holes (see Figure 22). Drill through the frame if there is no frame hole pattern.

  • Page 45: Removing The Installation Aids

    • Box unit • Universal unit The hydraulic unit is normally pre-assembled by PALFINGER Tail Lifts. On request, you can also obtain a box unit with long cables and hoses. You can mount this box unit at any position under the vehicle. In this case, bundle...

  • Page 46: Establishing Electrical Connections

    Please also refer to the PALFINGER Tail Lifts electrical circuit diagram supplied. You will find a copy of the electrical wiring diagram on the controller.

  • Page 47: Establishing Earth Connection

    Optional: ► Run the earth cable to the battery or to an earth bolt on the chassis. Shorten as required. ► Crimp the cable lug and mount it on the battery's minus terminal or on the earth bolt on the chassis. With vehicles with preinstalled ETMA interface: ►...

  • Page 48: 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 diagram, which you can obtain from PALFINGER Tail Lifts. Note:...

  • Page 49: Attaching The Control Panel Or Slimpanel

    8.5. Attaching the control panel or Slimpanel Figure 25: Control panel with control panel holder ► Fix the control panel holder or weld it in position. ► Mount the control unit on the control unit holder. Figure 26: Slimpanel with mounting brackets ►...
  • Page 50 Note: When fitting the control panel and the Slimpanel, observe the requirement of the EN 1756-1 standard for the distance of operating elements from the end of the superstructure. The distance L from the end of the superstructure to the centre of the control panel or Slimpanel must be 300 to 600 mm (see Figure 27).

  • Page 51: Connecting The Manual Cable Switch (Optional)

    8.6. Connecting the manual cable switch (optional) A manual cable switch or a radio remote control are optionally available for your PALFINGER Tail Lifts tail lift. Note: When installing a manual cable switch, you must attach the cable with socket under the vehicle loading area so that the cable can be connected to the manual cable switch.

  • Page 52: Radio Remote Control

    8.7. Radio remote control PALFINGER Tail Lifts optionally offers the Remote Control BT radio remote control (see Figure 29). Figure 29: Remote Control BT With a Remote Control BT, the recipient is already pre-assembled and only needs to be connected to the controller and fitted to the vehicle.

  • Page 53: Installing And Connecting The Platform

    Installing and connecting the platform WARNING! Risk of injury and damage to property if the tail lift is operated without a body! If the tail lift is operated without a vehicle body or without a loaded container, the lifting cylinder pistons can drive out of the cylinders. Risk of injury due to sudden lowering of the lifting mechanism and platform;...

  • Page 54: Moving Up And Positioning The Platform

    9.1. Moving up and positioning the platform ► Raise the platform with suitable lifting equipment such as a forklift truck, for example. Pad the lifting equipment with a suitable material to prevent damage to the platform. ► Bring the platform to the rear of the vehicle. Figure 30: Bringing the platform to the rear of the vehicle ►...

  • Page 55: Bolting The Platform To The Control Rod

    9.2. Bolting the platform to the control rod ► Make sure that the platform is in its final installation position. ► Bolt the cantilever heads of the platform to the control rods of the torsion frame. Insert the spacers provided to align the platform centrally with the superstructure (see Figure 31).

  • Page 56: Bolting The Platform To The Tilt Cylinders

    Cantilever head Bolt M12 Control rod Figure 32: Pin, lug 9.3. Bolting the platform to the tilt cylinders Depending on your tail lift model, you will need to bolt one or two tilt cylinders to the platform. ► Loosen the hose clamps of the bellows on the tilt cylinders and slide the bellows down (see Figure 33).
  • Page 57 ► Adjust the tilt cylinders’ length so that it possible to easily bolt the tilt cylinders to the platform. Operation of the tail lift: see operating instructions. ► During this procedure, hold the • the tilt sensor B15 with the cable pointing downwards (not necessary with the “Basic”...
  • Page 58 Cantilever head Bolt Bottom roller Tilt cylinder Figure 35: Bolting the tilt cylinder ► Screw on the lug with the M12 bolts (Tightening torque: 70 to 75 Nm). ► Fit the bottom rollers and secure them on each pin/locking screw with a snap ring (see Figure 36).

  • Page 59: Adjusting The Tilt Cylinders

    9.4. Adjusting the tilt cylinders Note: At the desired end position of the platform, the tilt cylinders must be extended to the stop. ► Close the platform to the extent possible (see operating instructions). The tilt cylinders are extended to the stop. ►...

  • Page 60: Installing Tilt Sensors

    9.5. Installing tilt sensors Depending on the selected equipment, the tail lift is delivered with a tilt sensor B15 or B15S (see Figure 34, page 57). 9.5.1. Installing tilt sensor B15 Figure 38 shows the cover cap with sensor holder for the tilt sensor B15 as delivered with the tail lift.
  • Page 61 Cover cap with sensor holder Tilt sensor B15 Figure 39: Cover cap with tilt sensor B15 ► Lay the cable of the tilt sensor B15 together with the cables for warning lights and foot switch along the torsion frame. Make a loop for the cable of the tilt sensor as strain relief.

  • Page 62: Installing Tilt Sensor B15S

    9.5.2. Installing tilt sensor B15S For the installation of the tilt sensor B15S, a platform connector is provided on the underside of the platform next to the right cantilever head (see Figure 40). The platform connector and the tilt sensor B15S are also used to supply power to the electrical components of the platform.

  • Page 63: 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: • adjusting the tilt sensor B15 or B15S (B15: see chapter 10.1, page 63;...

  • Page 64: Adjusting Tilt Sensor B15S

    10.2. Adjusting tilt sensor B15S DANGER! Danger to life and material damage in case of improper adjustment of tilt sensor B15S! If tilt sensor B15S is adjusted to a too steep inclination of the platform, the load may roll off the platform. There is a risk of serious or fatal injury to persons on the platform.
  • Page 65 ► Press one of the foot switches eight times. If there is no foot switch available: Give a plus pulse eight times to the plug location J3, pin 6, on the controller. To do this, you can tap plus from the pin next to it.

  • Page 66: Setting Tilt Switch B13

    10.3. Setting tilt switch B13 Note: If the tilt sensor B15 is present on the torsion frame of your tail lift, there is no need to set the tilt switch B13. ► Move the platform to the position horizontally approx. 250 mm above the ground as presented in Figure 43, page 66.

  • Page 67: Bleeding The Hydraulic Cylinders

    10.4. Bleeding the hydraulic cylinders To bleed the hydraulic cylinders of the tail lift: ► Switch on the tail lift (see operating instructions). ► Raise and lower the platform several times. Load the platform with the nominal load. ► Open and close the platform several times. ►...

  • Page 68: Bleeding The Hydraulic Cylinder (G < 450 Mm)

    10.5. Bleeding the hydraulic cylinder (G < 450 mm) Special procedure if the distance between the lifting mechanism and the ground is small (dimension "G" from the centre of the stand tube/linkage mount to the ground is less than 450 mm, see Figure 45, page 67): ►...

  • Page 69: Checking Alignment Of The Platform (Only Ptc 750 L, Llw)

    10.6. Checking alignment of the platform (only PTC 750 L, LLW) ► Move the platform horizontally to the end stop of the case and then back again a few millimetres. ► Position the platform parallel to the end stop using the adjusting screw on the tilt link (see Figure 46).

  • Page 70: Performing An Oil Level Check

    10.7. Performing an oil level check 10.7.1. Slide-in unit To check the oil level: ► Lower the tail lift so that it rests on the ground (see operating instructions). ► Retract existing support feet. ► Open the right cover of the stand tube. ►...

  • Page 71: Box, Universal Or Turning Unit

    10.7.2. Box, universal or turning unit To check the oil level: ► Remove the cover of the unit. ► Proceed as described in the previous chapter for slide-in units. 10.7.3. Recommended hydraulic oils • Shell Tellus S2 V 15 Operating temperature: -20 °C to 60 °C •...

  • Page 72: Adjusting The Pressure Relief Valve

    10.11. Adjusting the pressure relief valve ► Adjust the pressure relief valve so that the tail lift cannot lift more than 125% of its maximum load (see Figure 48). Note: For adjustment of the pressure relief valve, observe the chapter “Test by the assembler after assembly"...

  • Page 73: Adjusting The Pressure Switch Of The Hydraulic Support (Optional)

    10.12. Adjusting the pressure switch of the hydraulic support (optional) If the hydraulic support raises the vehicle too high or the props do not reach the ground, adjust the pressure switch of the support. ► For this purpose, turn the grub screw on the pressure switch (see Figure 49). Grub screw Pressure switch Hydraulic support...

  • Page 74: Final Work

    Final work 11.1. 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. 92-597.99-00.00-00).

  • Page 75: Performing Acceptance Test As Per Test Book

    “Confirmation by the installation firm” in the test book. Note: The test book as well as the further documents from the PALFINGER document pouch (operating manual, short operating manual, attachment report, certificates) should always be kept in the vehicle.
  • Page 76 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.

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