Palfinger C 1000 S Bedienungsanleitung

PALFINGER TAIL LIFTS

ASSEMBLY

INSTRUCTIONS

STANDARD TAIL LIFTS

LIFETIME EXCELLENCE

Dok: 07-500.99-04.10-03 Date: 19.06.2023

SNr: 2032342 Index: A25103

Assembly instructions

for

PALFINGER Tail Lifts

Standard tail lifts

Table of contents

1. About these assembly instructions..................................................7

1.1. Abbreviations used .................................................................. 7

1.2. Scope of delivery..................................................................... 7

1.3. Enclosed documents ............................................................... 8

2. Important safety information.............................................................9

2.1. Personnel qualifications........................................................... 9

2.2. Warning notices in these assembly instructions..................... 10

2.3. You must take these points into account during

assembly ............................................................................... 11

2.3.1. General information.................................................... 11

2.3.2. Before starting assembly............................................ 11

2.3.3. During assembly ........................................................ 12

2.3.4. During initial commissioning....................................... 12

3. Required tools and auxiliary equipment ........................................13

4. Model line .........................................................................................14

4.1. Standard tail lift, overview...................................................... 15

4.2. Tail lift with welded consoles and slide-in unit........................ 16

4.3. Tail lift with bolted consoles and slide-in unit ......................... 17

4.4. Tail lift with platform and turning unit ..................................... 18

4.5. Tail lift without torque support................................................ 19

4.6. Tail lift with torque support..................................................... 20

5. Preparing for assembly ...................................................................21

6. Preparing the vehicle.......................................................................23

6.1. Removing projecting parts of the vehicle ............................... 24

6.2. Creating cut-outs for the lifting mechanism (optional) ............ 24

6.3. Reinforcing rear cross-member (optional).............................. 25

6.4. Preparing vehicles with box bodies........................................ 25

7. 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. Positioning lifting mechanism under

the vehicle .................................................................. 34

7.2.2. Positioning and fixing the installation aids

on the vehicle chassis ................................................ 35

7.2.3. Bolting the lifting mechanism to the

installation aid............................................................. 36

7.2.4. Positioning the stand tube / linkage mounts................ 39

7.2.5. Fixing the console plates on the vehicle chassis......... 41

7.2.6. Removing the installation aids .................................... 45

7.3. Installation of the hydraulic unit .............................................. 45

8. Establishing electrical connections............................................... 46

8.1. Establishing the connection to the vehicle battery.................. 46

8.2. Establishing earth connection ................................................ 47

8.3. Connecting the acoustical signal generator............................ 47

8.4. Installing and connecting the control unit ............................... 48

8.5. Attaching the control panel or Slimpanel ................................ 49

8.6. Connecting the manual cable switch (optional) ...................... 51

8.7. Radio remote control.............................................................. 52

9. Installing and connecting the platform.......................................... 53

9.1. Moving up and positioning the platform.................................. 54

9.2. Bolting the platform to the control rod..................................... 55

9.3. Bolting the platform to the tilt cylinders................................... 56

9.4. Adjusting the tilt cylinders....................................................... 59

9.5. Installing tilt sensors............................................................... 60

9.5.1. Installing tilt sensor B15.............................................. 60

9.5.2. Installing tilt sensor B15S ........................................... 62

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. Checking alignment of the platform

(only PTC 750 L, LLW) .......................................................... 69

10.7. Performing an oil level check................................................. 70

10.7.1. Slide-in unit ................................................................ 70

10.7.2. Box, universal or turning unit...................................... 71

10.7.3. Recommended hydraulic oils ..................................... 71

10.8. Lubricating the bearing .......................................................... 71

10.9. Checking bolted connections................................................. 71

10.10. Checking hoses and cables................................................... 71

10.11. Adjusting the pressure relief valve ......................................... 72

10.12. Adjusting the pressure switch of the hydraulic support

(optional) ............................................................................... 73

11. Final work.........................................................................................74

11.1. Attaching warning strips and type plate ................................. 74

11.2. Performing acceptance test as per test book ......................... 75

1. About these assembly instructions

These assembly instructions contain important information to ensure that the

PALFINGER Tail Lifts tail lift is safely and properly assembled.

Some texts in this manual have a special purpose and are marked as

follows:

•Listing

►Instruction for action

►Read these assembly instructions all the way through, particularly the

chapter “Important safety information" on page 9, before attaching the tail

lift.

►Observe all the generally applicable statutory and other binding European

and national regulations on accident prevention, handling hazardous

substances and on environmental protection.

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.

1.3. Enclosed documents

In addition to these assembly instructions, you will receive additional

documents with your PALFINGER Tail Lifts tail lift.

►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:

•Assembly drawing (optional)

•Attachment report/attachment diagram (if requested)

•Test book

•Operating instructions

•Short operating manual

•Assembly instructions (short form)

•Underrun protection unit certificate

•Small and large test plate

•ETMA adhesive decal

•Type plate

•Assembly instructions for warning flags

•Electrical circuit diagram

2. 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.

►Read this assembly manual thoroughly all the way through, before

mounting the PALFINGER Tail Lifts tail lift.

►Keep the assembly instructions at hand in a good condition so that they

are always legible. Make sure that they are available to all responsible

fitters at all times.

►Always ensure that these assembly instructions and the supplied

documents are always passed on along with the PALFINGER Tail Lifts

tail lift to third parties.

2.1. Personnel qualifications

The assembly and commissioning of the PALFINGER Tail Lifts tail lift

require systematic knowledge of mechanical, electrical, hydraulic systems as

well as familiarity with the associated specialist terms. Consequently to

ensure operational safety these activities may only be executed by trained

and authorised specialists, who have been instructed in safety engineering

aspects, or by an instructed person working under the supervision of a

specialist.

A specialist is a person who, due to their specialised training, knowledge and

experience, as well as knowledge of the applicable regulations, can evaluate

the tasks assigned to them, recognise possible dangers, and implement

suitable safety measures. A specialist must comply with the applicable

technical rules.

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.

►Description of measures for avoiding danger.

•The warning triangle indicates a risk of fatal or severe injuries.

•The signal word indicates the severity of the danger. The signal words

have the following meanings:

Signal word Meaning

DANGER! Indicates an imminent, major hazard that is certain to

result in serious injury or even death if the hazard is not

avoided.

WARNING! Indicates a potential hazard that may result in serious

injury or even death if the hazard is not avoided.

CAUTION! Indicates a potentially hazardous situation which, if not

avoided, may result in moderate or minor injury or

property damage.

Note: If you do not observe this information, the assembly

process may be adversely affected.

•The paragraph “Type and source of hazard” describes the nature and

source of the danger.

•The paragraph “Consequences” describes possible consequences of

ignoring the warning.

•The “Avoidance of hazard” paragraphs indicate how to avoid the danger.

It is essential that the measures to avert danger are complied with.

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