Palfinger PTV 33 Installation Manual Download

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PTV 33/44/55/66 Installation Manual

Rev. 1.1

Manual Updates

Revision

Description

v1.0

•

Initial Release

Summary of Contents for PTV 33

Page 1: ...PTV INSTALLATION MANUAL PTV 33 3300 lbs Capacity PTV 44 4400 lbs Capacity PTV 55 5500 lbs Capacity PTV 66 6600 lbs Capacity 05 21...

Page 2: ...ge without notice Visit www palfinger com for up to date information and notifications If you received this product with damaged or missing parts contact Palfinger Liftgates at 888 774 5844 Parts Orde...

Page 3: ...sions Width Requirements 17 8 4 Strength Requirements 18 9 Body Preparation 19 9 1 Rear Bumper 19 9 2 Tow Hitch Auxiliary Equipment 20 9 3 Flush the Sill Sub Framing 21 9 4 Support Body 24 10 Liftgate...

Page 4: ...Routing Wiring Crimping 56 13 6 Circuit Breaker at Enclosure 57 13 7 Battery Wiring Truck Kit 58 13 8 Battery Wiring Trailer Kit 59 13 9 Electrical Schematic 61 13 10 Control Board System Codes 62 13...

Page 5: ...isor Name Trailer Truck Year Make Model Liftgate Information Liftgate Serial Number Liftgate Model Number Date of Purchase Date of Installation 15939 Piuma Ave Cerritos CA 90703 Tel 888 774 5844 Fax 5...

Page 6: ...PTV 33 44 55 66 Installation Manual Rev 1 1 4 1 Manual Updates Revision Description v1 0 Initial Release...

Page 7: ...lt in death or serious injury WARNING indicates potentially hazardous situation which if not avoided could result in death or serious injury CAUTION indicates a potentially hazardous situation which i...

Page 8: ...ions before adding any auxiliary equipment The installer is responsible for compliance with this manual OEM and FMVSS requirements The installer should never place any portion of him herself or any ot...

Page 9: ...only the PTV series liftgate which is designed for different capacities There are four options available to determine the model and serial number of the installed liftgate 1 Refer to the serial number...

Page 10: ...i Meter Snap Ring Pliers Hammer SAE Metric Allen key Set Impact Sockets SAE Metric Socket Set Assorted Drill Bits Floor Jack or Equivalent Sm To Med Bottle Jack Forklift or Overhead Hoist Handheld Gri...

Page 11: ...nents Single Pump KET06882A Cable 11 3 8 Lugs 2GA Red 1 pc KET06062A Bus Bar Red 2 pcs KET05916A Bus Bar Black 2 pcs EM 781 Nut Serrated 3 8 16 SS 6 pcs Electric Components Dual Pump KET06882A Cable 1...

Page 12: ...pport Chains Right Side Column Traverse Main Control Switch Load Center Left Side Runner Right Side Runner Aluminum Retention Ramp Fixed Ramp Fixed Ramp w Cart Stops Ramp options shown below are steel...

Page 13: ...eakers Auxiliary Remote Control Cable Entry Ports Hydraulic Enclosure Dual Pump Configuration Hydraulic Enclosure Single Pump Configuration Secondary Pump Motor Control Board Primary Pump Motor Batter...

Page 14: ...________ L Frame Height Height of chassis frame ________ Truck Information Truck Dimensions Type of Body check applicable Van Flatbed Reefer Other specify ____________ Type of Rear Door check applica...

Page 15: ...the trailer slider holes ________ X Eyebrow depth ________ Z Top of floor where the liftgate platform will meet the top of the eyebrow ________ Customer Information Quote SO _________________________...

Page 16: ...annot be installed with barn or full opening swing door types Trucks need to be 26 000 lbs GVWR Gross Vehicle Weight Rating and above It is not recommended to cut torch or remove the support materials...

Page 17: ...your gate is compatible with your vehicles bed height Liftgate Model Platform Depth Platform Width Based on Vehicle Width Dock Loading Bed Height Range NO Dock Loading Bed Height Range 96 W 102 W Min...

Page 18: ...at your gate is compatible with your vehicles bed height Liftgate Model Platform Depth Platform Width Based on Vehicle Width Dock Loading Bed Height Range NO Dock Loading Bed Height Range 96 W 102 W M...

Page 19: ...Width Outside Column Dim Inside Column Dim Inside Platform Chain Plate Overall Outside Dim Overall Liftgate Dim H xW 96 Wide Body 94 7 16 84 3 8 78 5 8 95 7 16 90 5 16 x 95 7 16 94 7 16 78 5 8 95 7 1...

Page 20: ...post and rear sill strength requirements are met for your liftgate Truck body or trailer must be capable of supporting minimum forces and loads shown below Side Wall Requirements PTV 35 PTV 44 PTV 55...

Page 21: ...rface for the liftgate It is not recommended to cut torch or remove the support materials from the rear sill of the truck or trailer Installers are advised to sub frame or flush sills as required Remo...

Page 22: ...they must not stick out further than the rear sill Relocate or remove tow hitch or other auxiliary equipment if necessary Fig 3 If the tow hitch or other auxiliary equipment must be removed or adjuste...

Page 23: ...16 or greater wall tubing before liftgate is mounted Or the liftgate can be mounted into position and the sub frame can be built as the liftgate is installed with 3 16 or greater flat bar Fig 5 In ei...

Page 24: ...PTV 35 44 55 66 Installation Manual Rev 1 1 22 Tubing Subframe Flat Bar Subframe 2 pcs per Column Liftgate Column Liftgate Column Vehicle Corner Post Vehicle Corner Post Fig 5...

Page 25: ...uld NOT be removed It is recommended to use flat bar with the same thickness as the stiffeners typically to 3 8 thick x 3 wide The liftgate Installation weld procedure is the same Corner Stiffener Cor...

Page 26: ...support is required add support bars as shown below Flatbed installations may use a similar arrangement with 3 16 x 4 x 4 min rectangular tubing for corner posts and 3 channels for support bars 72 Ap...

Page 27: ...ve Shipping Bands Remove bands Cut the bands from the front and rear of the liftgate and the rear The hat section s are banded to the column cut the bands to remove hat sections The light and control...

Page 28: ...te Ready for Installation After removal of the shipping bands and the hydraulic enclosure the liftgate is ready for installation as shown below DO NOT remove any braces before or during installation u...

Page 29: ...ounting the Liftgate Standard Installation Before positioning the liftgate consider when measuring and centering the liftgate that the truck or trailer may NOT be perpendicular to the ground Special c...

Page 30: ...the top of the liftgate tight against the body for welding Liftgate Column Forklift Forks Horizontal Top Brace 4 x4 x24 Woodstock Clamp 3 Remove Shipping Stand Hoist the liftgate approximately 8 off t...

Page 31: ...the lifting device and not the alignment plates Fig 7 Do not remove the lifting device 4 Fit Liftgate Against Truck Use a forklift recommended to position the liftgate flush against the vehicles corn...

Page 32: ...dges of the columns to the edges of the vehicle using a measuring tape Measure at the top of the columns and the at bottom both measurements must be the same Fig 8 If both sides don t measure equally...

Page 33: ...ns are square and parallel Use a framing square to verify columns are square at 90 to the vehicle s sill and body Measurements should reflect dimensions below when measured from the indicated points 1...

Page 34: ...all mounting dimensions are correct check to ensure that the floor and traverse are flush and that the columns are flush to the vehicle F Style Clamps F Style Clamp Vehicle Corner Post Liftgate Colum...

Page 35: ...n be added in the corner to minimize pull from welding Fig 10 Round Stock Vehicle Corner Post Vehicle Corner Post with Radius Bumper Plate Bumper Plate Vehicle Corner Post Dock Bumper Top View Left Si...

Page 36: ...lds Weld inside of columns from top to bottom Curb side column shown below repeat welding procedure on street side column 3 Traverse Welds Weld traverse per vehicle width 96 W or 102 W as shown below...

Page 37: ...a weld on the dock bumpers as shown and x 3 welds 5 places evenly spaced on columns top to bottom Do not weld near the control area Fig 11 Repeat welding procedure on the street side column DO NOT WEL...

Page 38: ...forklift Second remove the clamps and finally remove the liftgate braces Remove all clamping devices Unbolt Top Brace 4X Remove Top Brace Remove all clamping devices Remove Bottom Brace Remove Forkli...

Page 39: ...talled Method 1 Factory Installed The liftgate arrives from the factory with the Vehicle Brackets installed on the liftgate Vehicles Brackets will be secured to the liftgate columns at the top and bot...

Page 40: ...g and Welding procedures from Sections 10 11 3 Finalizing Installation To finalize this method of installation both column wraps on the liftgate must be welded to the vehicle in the location shown bel...

Page 41: ...lt On Subframe Vehicle Bracket and Bridge Liftgate Columns w Alignment Buttons Vehicle Bracket Button Slots Alignment Buttons on Liftgate Columns Liftgate Traverse Liftgate Alignment Plate Vehicle Rea...

Page 42: ...ate columns become flush with the Vehicle Brackets Slowly lower the forklift forks hoist so that all buttons are seated properly in the vehicle bracket slots Alignment Buttons on Front Surface of Colu...

Page 43: ...secure the top section of the column to the vehicle bracket After installing the bolt reinstall the column caps back to the column using the same hardware Torque 5 8 bolts to 204 ft lbs Column Cap Bo...

Page 44: ...in the wheelbase and forward of the rear wheels when permitted B Relocation Hose Kit 1 C Relocation Hose Kit 2 D Relocation Hose Kit 3 Side View Right Side A Standard Hose Kit Shipped Standard w lift...

Page 45: ...ure Weld the enclosure to body cross members with x 1 1 4 welds Weld to a minimum of four 4 crossmembers Weld front rear and sides of angles at each crossmember Observe the recommended welding practic...

Page 46: ...reinstall the four nuts on the enclosure Remove Four Nuts Only Shipping Braces 12 4 Hydraulic Connections To open the lid of the box remove the security bolt below the lid handle Pump and Motor fittin...

Page 47: ...ber Secure with thread cutting flange screws Hydraulic Enclosure Security Bolt Bottom View of Vehicle Curb Side Column Hat Section Hydraulic Enclosure Drill Holes Through Hat Section and Crossmember F...

Page 48: ...ness can be found Position hoses opposite to each other 3 8 hoses should have one male and one female exposed at each end Position the hoses in the same manner one male and one female at each end Fig...

Page 49: ...annot be installed due to the construction of the vehicle connect the male and female hoses going to the hydraulic enclosure directly to the hydraulic junction block Fig 15 1 4 90 Elbow 3 8 90 Elbow 3...

Page 50: ...lic Enclosure Remove the plugs and caps Fig 16 from the side of the hydraulic pump and motor enclosure Hat Section Hoses from Column Caps Plug Plug Route the hoses coming from the column over to the h...

Page 51: ...Side of Hydraulic Enclosure Screw Lock Nut Volt Meter On the inside of the Hydraulic Enclosure open the control board cover by pulling the side of the rubber cover out of the locking tab Unhook the t...

Page 52: ...ed Fig 21 At the hydraulic enclosure entry cut one grommet as shown in Fig 19 and fit the cut grommet over the J11 harness Position the J11 harness with grommet in one of the grommet slots on the cove...

Page 53: ...g hole pattern below and mount the switch with the provided screws Fig 22 Wire the switch and harness per diagram Test the switch After testing and making sure the switch is functioning properly place...

Page 54: ...Ave Cerritos CA 90703 M 207 BAR 3000 PSI A B 69 BAR 1000 PSI C D 1 72 CC REV 0 105 IN REV T1 P1 M 1 72 CC REV 0 105 IN REV S1 S2 S5 S4 S3 M S1 LIFT M S2 S5 POWER DOWN S5 GRAVITY DOWN M S4 TILT OPEN M...

Page 55: ...Installed from Factory Property HYDREX MV ARCTIC 15 Start Up Temperature 50 C 58 F Operating Temperature 45 C to 23 C 49 F to 73 F Pour Point 57 C 71 F Flash Point 128 C 262 F Density 15 C 59 F kg L...

Page 56: ...raided hoses and other vehicle components Never exceed rating of existing fuses located at the battery control board and or the pump and motor which may result in serious damage to the equipment Never...

Page 57: ...enclosure with positive terminals to the right side as shown Secure the batteries to the box with the battery strap kit 3 Battery Strap Kit and Buss Bars Secure the batteries to the enclosure with the...

Page 58: ...he wire along the wooded spacer with insulated cable clamps Body Long Sill Wooden Spacer s Chassis Frame U Bolt Cable Routed Outside of U Bolts w Slack Insulated Cable Clamps Cable Routed on Inside of...

Page 59: ...eakers Circuit Breaker Primary Pump Motor Power Cable Dual Pump Motor Circuit Breaker Configuration Single Pump Motor Circuit Breaker Configuration Power Cable To Batteries Power Cables To Batteries O...

Page 60: ...it Single Pump Aux Battery 40 ft 36 11 74 Circuit Breaker Flag Reset Positive Ground Charging Circuit Breaker Auto Reset Starter Solenoid 2 Motor 2 Motor 1 Auxiliary Batteries Master Shut Off Switch G...

Page 61: ...Pump Single Pole Aux Battery 40 ft 36 11 74 Charging Circuit Breaker Auto Reset Starter Solenoid Motor 1 Auxiliary Batteries Ground to Trailer Side Rail Master Shut Off Switch 12V Trailer Kit Single...

Page 62: ...y Trailer Socket Single Pole 40 ft 36 11 74 11 36 Positive Ground Charging Circuit Breaker Auto Reset Starter Solenoid 2 Starter Solenoid 1 Motor 2 Motor 1 12v Battery Ground to Trailer Side Rail Mast...

Page 63: ...A 90703 70 1121 001_a PTV Electrical Schematic Power LED Volt Gauge Ground to Chassis Master Shut Off Switch Pump and Electric Motors 15 A Fuse 15 A Fuse Cab Shutoff Switch Optional Valves Power Sourc...

Page 64: ...or disconnect bridge J11 2 4 or close tail lift 8 General short in electric wiring Cab switch off on or disconnect bridge J11 2 4 or voltage interruption MBB control 9 Defect at motor solenoid detect...

Page 65: ...n tractor including ground 2 Trailer Test Ground battery load tester on trailer chassis point C Connect positive cable on positive pole of single pole plug receptacle on trailer B Run load test This w...

Page 66: ...light harness to avoid any of the sharp edges on the liftgate columns Tail Light Adapter Harness Palfinger Liftgates will provide harness adapters that will are plug and play and compatible with diffe...

Page 67: ...ing liftgate to service Liftgates with Fixed Ramps have 9 grease fittings Liftgates with Aluminum Retention Ramps ARR have 11 grease fittings Use a light penetrating oil on closing aids For power clos...

Page 68: ...se this lift gate for anything but it s intended use The lift gate is not equipped with a back up system to prevent falling in the event of a failure BEFORE OPERATING LIFT BE SURE YOU UNDERSTAND OPEN...

Page 69: ...PTV 35 44 55 66 Installation Manual Rev 1 1 67 G A K C F D B H E G E D J N N M M...

Page 70: ...mmended that the installer refer to the Code of Federal Regulations CFR which can be viewed at http ECFR gpoaccess gov H Dimension 15 H 60 from ground to center of tape Requirement 3 Red white reflect...

Page 71: ...s will confirm all controls work correctly and hydraulic system is completely bled of air 16 2 Operating Instructions Standard Units Steps 1 Turn on power To activate power to the liftgate turn the ma...

Page 72: ...a around platform is clear before opening platform Pushing the DOWN button and OPEN button together to power the platform open OPEN DOWN 3 Lower the platform to the ground Pushing the DOWN button lowe...

Page 73: ...push the UP button for thirty 30 seconds This will bypass hydraulic fluid through hydraulic poppet valves located in each of the lift cylinder pistons returning hydraulic fluid back to the reservoir...

Page 74: ...down platform past the Travel Locks See Illustration DOWN 8 Raise the Platform Using the UP button raise platform up until travel ears clear the travel lock slot See Illustration UP 9 Lock the Platfor...

Page 75: ...o liftgate components Be sure to inspect the liftgate for damage Front View of Liftgate Dock Stops on Traverse Hooks on Side of Platform Sidebar 1 Using the UP button to power platform up so that it i...

Page 76: ...nes are secured with cable ties clamps or other fasteners and are away from sharp edges and moving parts Circuit Breakers installed and wired per instructions Lights wired properly and operate per DOT...

Page 77: ...PTV 35 44 55 66 Installation Manual Rev 1 1 75...

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