Related Manuals for Palfinger PTV
Summary of Contents for Palfinger PTV
- Page 1 Model PTV Liftgate Training, Troubleshooting & Maintenance Manual Training Manual REV-07062022...
- Page 2 SALES AND TECHNICAL INFORMATION ALL MODELS OF PALFINGER LIFTGATES Installation, Operator(Owner) and Parts Manuals are available for download or viewing on our website at https://www.palfinger.com/en-US/usa/products/lift-gates. Additionally, troubleshooting guides, hydraulic and electrical schematics are available for download and/or viewing. Diagrams of decal placement are in the Installation and Operator Manuals. Decals are furnished at no cost to our customers.
- Page 3 State of Charge vs Open Circuit Voltage, OPEN CIRCUIT VOLTAGE FLOODED % CHARGE 12.6-12.7 12.8 or HIGHER 12.4 12.6 12.2 12.3 11.8 11.8...
- Page 4 TRACTOR TO TRAILER GROUND TEST...
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Page 5: Voltage Test
10-10 VOLTAGE TEST PRIOR TO TROUBLESHOOTING PERFORM BATTERY VOLTAGE TEST IF OPEN CIRCUIT BATTERY VOLTAGE IS LESS THAN 12.5V (80%) RECHARGE BATTERIES BEFORE PROCEDING ALL TESTS ARE PERFORMED WITH ENGINE OFF AND TRAILER DISCONNECTED FROM TRACTORS • MAKE SURE MASTER DISCONNECT SWITCH ON RIGHT SIDE OF BATTERY BOX IS ON •... - Page 6 CIRCUIT BOARD POWER CONNECTIONS 1. #1 & #2 Black wire connect to fuse holder and supply power to Terminals #27 & #2 on J1 Plug. 2. #3 Black wire & Green/Yellow wire connect to Ground Stud on Primary Motor suppling ground to J2 Plug. 3.
- Page 7 BATTERY CONNECTION INFORMATION...
- Page 8 BATTERY CONNECTION INFORMATION Must have two positive cables one from each end battery positive post going to master switch...
- Page 9 BATTERY CONNECTION INFORMATION...
- Page 10 BATTERY CONNECTION INFORMATION...
- Page 11 BATTERY CONNECTION INFORMATION Must have two positive cables one from each end battery positive post going to master switch...
- Page 12 BATTERY CONNECTION INFORMATION Must have two positive cables one from each end battery positive post going to master switch...
- Page 13 PTV Serial number Tag location...
- Page 14 PTV Liftgate Components...
- Page 15 PTV Liftgate Pump Box Components Electrical Schematic Circuit Board Fault Codes...
- Page 16 PTV Liftgate Primary Pump & Motor Components NOTE: Items 6 & 7 valves are the same as on Previous models...
- Page 17 PTV Liftgate Secondary Pump & Motor Components...
- Page 18 Circuit Board Overview - PTV ❖ ALL NUMBERS ON THE BOARD *BL- blue * BR- brown * SW-black * GE-yellow * GN-green * - Negative * + 12 Volts ARE PLUG POSITION NUMBERS GROUND for ❖ 2 DIGIT LETTER MARKINGS...
- Page 19 PTV ELECTRICAL SCHEMATIC...
- Page 20 PTV Hydraulic Schematic...
- Page 21 PTV Pump Box Components Hand held remote Hydraulic Primary & Secondary Voltmeter Pressure Motor Gauge Hydraulic Reservoir Charge Line Auto Circuit breaker 175 amp 175 Amp Circuit breakers Circuit Board Master Disconnect Switch Primary S-5 Valve Secondary Motor Motor Pilot Valve...
- Page 22 PTV Pump Valve Setup Circuit board cover S4 Valve S1 Valve Open Lift S3 Valve Close S2 Valve Lower S5 Valve Lower Fluid Return...
- Page 23 PTV Primary Pump Valve Block Setup Circuit board cover S4 Valve-Open S1 Valve-Lift S3 Valve-Close S2 Valve-Lower Pilot Operated Check Valve S5 Valve-Lower Return Fluid High Pressure control valve Low Pressure control valve...
- Page 24 PTV Primary Pump Valve Block Setup Location of Pilot Operated Check Valve for Open & Close Circuit board cover Pilot Operated Check Valve located behind ¼” Allen plug use needle nose plyers to remove Allen Plug Removed S5 Valve Pilot Operated...
- Page 25 PTV Electrical Control Overview of Circuit Board, Connectors and Electrical Schematic LED flashes green when OK LED flashes red when a fault exists LED in lower left corner shows code for fault...
- Page 26 PTV Circuit Board – M Control Fault Codes Code: Description Reason: Solution 1: Solution 2: Solution 3: Solution 4: Solution 5: System OK / control System OK / control system: OFF System OK / control system: OFF system: OFF System OK / control...
- Page 27 Clear Fault Code on MBB Control Circuit Board NOTE: Always start with turning the Master switch off first and make sure the fault code goes off showing Power for Circuit Board is connected correctly, This may also clear the code. Reconnect plugs in this order on Circuit Board.
- Page 28 PTV-Electric/Hydraulic Function Open Platform 1. S4 Valve open 2. One Motor Runs (Selected by PC Board) GROUND for Voltage FUSE PC BOARD TO NEG. BAT. gauge LIFT CYLINDERS NOTE: ROADSIDE CYLINDER LARGER DIAMETER POST NOT USED FOR ILD+ LIFT CYLINDERS...
- Page 29 PTV-Electric/Hydraulic Function Lower – Power Down 1. S2 & S5 Valve Open 2. One Motor Runs (Selected by PC Board) GROUND for Voltage FUSE PC BOARD gauge TO NEG. BAT. LIFT CYLINDERS NOTE: ROADSIDE CYLINDER LARGER DIAMETER POST NOT USED FOR ILD+...
- Page 30 PTV-Electric/Hydraulic Function Lower – Gravity Down 1. S5 Valve Open 2. S2 Valve Open GROUND for Voltage FUSE PC BOARD gauge TO NEG. BAT. LIFT CYLINDERS NOTE: ROADSIDE CYLINDER LARGER DIAMETER POST NOT USED FOR ILD+ LIFT CYLINDERS NOTE: ROAD SIDE...
- Page 31 PTV-Electric/Hydraulic Function Lift 1. S1 valve open 2. Both Motors Run GROUND for Voltage FUSE PC BOARD TO NEG. BAT. gauge LIFT CYLINDERS NOTE: ROADSIDE CYLINDER LARGER DIAMETER POST NOT USED FOR ILD+ LIFT CYLINDERS GROUND for Voltage FUSE PC BOARD...
- Page 32 PTV-Electric/Hydraulic Function Close Platform 1. S3 Valve Open 2. One Motor Runs (Selected by PC Board) GROUND for Voltage FUSE PC BOARD LIFT CYLINDERS NOTE: ROADSIDE CYLINDER LARGER DIAMETER TO NEG. BAT. gauge POST NOT USED FOR ILD+ LIFT CYLINDERS...
- Page 33 How to check coils for resistance Set voltmeter to OHM function. Place a probe on each node of coil. If reading shows 5.5. to 7.0Ω Coil is good If reading shows .0Ω Coil is shorted out. Replace. If reading shows .Overload Coil is damaged by burn or physical damage.
- Page 34 Bucher S5 Valve Comparison to Hydac Single Release Valve The stem in the Bucher is longer and the Coil itself is longer but both valves interchange 0.6” 0.6” 20 MM Threads on Both Valves 1” Hydac Single Lock Release Valve Palfinger Part # P-67282345...
- Page 35 Bucher Two Way Release Valve Comparison to Hydac Two Way Release Valve The stem in the Bucher is longer and the Coil itself is longer but both valves interchange BUCHER TWO WAY RELEASE VALVE 2.4" HYDAC TWO WAY RELEASE VALVE P-2021832A 0.6"...
- Page 36 First Inspection, Lift Gate Condition 1) Damage to lift gate : Broken or Missing Parts . 2) Battery connections clean and tight , No corrosion. 3) Lift gate wiring clean and tight , No damage , No corrosion. 4) Burnt fuse , Tripped circuit breaker. 5) All plugs in correct location on PC board , No corrosion .
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Page 37: Troubleshooting Section
TROUBLESHOOTING SECTION BEFORE DOING 10 -10 TEST : 1. SHUT OFF TRUCK ENGINE. 2. UNHOOK CHARGE COIL FROM TRACTOR . 3. SHUT OFF BATTERY CHARGER . 4. DISCONNECT ANY OUTSIDE BATTERY SOURCE. CONFIRMING BATTERY VOLTAGE WITH 10 -10 TEST : USING A MULTIMETER , SET ON DC VOLTAGE . -
Page 38: Motor Not Running
LIFT GATE NOT WORKING HEAR NO SOLENOIDS CLICKING HEAR SOLENOIDS CLICKING 1. CHECK FUSES AT PC BOARD 1. CHECK CIRCUIT BREAKER AT BATTERIES 2. CHECK FOR BAD SWITCHES 2. GO TO : MOTOR NOT RUNNING 3. CHECK FOR BAD MOTOR SOLENOID BAD SOLENOID VALVE MOTOR NOT RUNNING 1. - Page 39 LIFT GATE NOT WORKING TURN ON CAB SWITCH , TRUCK TURN ON ,SWITCH AT LIFTGATE, TRAILER CIRCUIT BREAKER FOR MOTORS CHECK FUSE AT MASTER SWITCH UNPLUG J30 CONNECTIONS ON PC BOARD: J-30 MAIN CONTROL AND TOGGLE SWITCH TRY OPERATIONS WITH HAND CONTROL REMOTE IN PUMP BOX IF OPERATIONS ARE OK PROBLEM IN J30 HARNESS OR SWITCHES M CONTROL CHECK FAULT CODES CLEAR CODE , UNPLUG J-11 &...
- Page 40 LIFT GATE NOT LIFTING S1 VALVE NOT OPENING ALONG WITH MOTOR LIFT GATE NOT LOWERING (GRAVITY DOWN) S-5 VALVE NOT OPENING LIFT GATE NOT LOWERING (POWER DOWN) S-2 AND S-5 VALVE NOT OPENING ALONG WITH MOTOR LIFT GATE NOT OPENING UP S-4 VALVE NOT OPENING ALONG WITH MOTOR OR CHECK RESTRICTOR AT OPEN AND CLOSE CYLINDER LIFT GATE NOT CLOSING...
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Page 41: Checking And Changing The Oil
Bleeding Hydraulic System All Palfinger Liftgates have Vented caps on Reservoir and will Push air in Hydraulic System back to Reservoir and out vented cap by just running the liftgate through normal cycles and keeping Hydraulic fluid at the proper level in Reservoir during this process. -
Page 43: Maintenance And Care
Maintenance and Care... - Page 44 Lubrication CAUTION DO NOT grease the Slide Pads or Columns or Runners, as this will VOID your WARRANTY on the Slide Pads. . Liftgates with Fixed Ramps have 10 grease fittings . Liftgates with Aluminum Retention Ramp (ARR) have 12 grease fittings .
- Page 45 PTV-PREVENTIVE MAINTENANCE GUIDELINES 1) Visual check of Liftgate for mechanical damage (bent or broken parts) 2) General function check - Cycle Liftgate through every function to make sure Liftgate is working correct - Lift, Lower, Open, Close – Lower for Dock Loading...
- Page 46 PTV-PREVENTIVE MAINTENANCE GUIDELINES Common hydraulic pressure on gauge. Grease Fitting Locations Attention: A drop in Voltage under 10 Volts can indicate a low voltage situation 10) Check every lock bolt on pin plate for tight fit total of 8 lock bolts...
- Page 47 PTV-PREVENTIVE MAINTENANCE GUIDELINES 12) Check all chain attachment points make sure chains are adjusted even. Road Side Top Curb Side Top Road Side Curb Side Grease Fitting Locations Chain U-Bolt Chain U-Bolt U-Link U-Link Road Side Bottom Cylinder Curb Side Bottom Cylinder Grease Grease fitting &...
- Page 48 PT, Monday thru Friday 5:00pm ET, Monday thru Friday Jorge Gallardo – Asst. Tech Support and Warranty Ben Styer – Parts Asst. / Technical Support Manager 609-587-4200 562-252-0407 b.styer@palfinger.com James Ross – Parts Asst. j.gallardo@palfinger.com Rey Rodriguez – Parts Asst. 609-587-4200 562-252-0410 j.ross@palfinger.com Sean Gettler –...
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Questions and answers
Every 5th or 6th pole it lift
A possible cause for a Palfinger PTV lifting only every 5th or 6th pole could be due to inconsistent valve operation or an issue with the PC board selecting the motor. Specifically, the system uses S2 and S5 valves to control lift, and one motor is selected by the PC board. If either valve does not open reliably or if the PC board fails to select the motor correctly, the lift function may only activate intermittently.
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