Palfinger MBB C 1000 L, Assembly Instructions Manual

Page 1: ...PALFINGER TAIL LIFTS ASSEMBLY INSTRUCTIONS TAIL LIFTS STANDARD ...

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Page 3: ...Assembly instructions for PALFINGER Tail Lifts Tail Lift Standard 07 500 99 04 10 03 13 09 2019 Ref no 2032342 A 23591 ...

Page 4: ...g cutouts for the lifting mechanism optional 21 6 3 Reinforcing rear cross member optional 21 6 4 Preparing vehicles with box bodies 22 7 Installing lifting mechanism 23 7 1 Installation with installation aids 23 7 2 Installation with attached platform 32 8 Establishing electrical connections 36 8 1 Establishing connection to vehicle battery 36 8 2 Installing and connecting the control unit 38 8 3...

Page 5: ...51 10 3 Checking horizontal position on ground 51 10 4 Performing an oil level check 52 10 5 Checking screw connections 53 10 6 Attaching warning strips and type plate 54 10 7 Adjusting the optional pressure switch of the hydraulic support 54 10 8 Performing acceptance test as per test book 56 11 Index 57 12 Hydraulic circuit diagrams 59 ...

Page 6: ...s is provided below 1 2 Enclosed documents In addition to this assembly manual you will receive additional documents with your PALFINGER Tail Lifts tail lift They form part of these assembly instructions and should be observed 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 ...

Page 7: ...7 About these instructions Brief operating instructions Type plate Attachment report attachment diagram General installation drawing ...

Page 8: ... 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 and pneumatic systems as well as familiarity with the associated specialist terms Consequently to ensure operational safety these activities may only be ...

Page 9: ...al that the measures to avert danger are com plied with The signal words have the following meanings SIGNAL WORD Description of type and source of the danger Description of consequences of non observance Description of measures for avoiding danger Signal word Application DANGER Indicates a danger that will certainly result in death or severe injury if you fail to avoid it WARNING Indicates a dange...

Page 10: ...fts Observe the respectively applicable general attachment report attachment diagram from PALFINGER Tail Lifts Make sure that any welding work is only performed by certified welders It is essential to comply with the vehicle maker s specifications as well as the applicable standards and regulations for welding work 2 3 2 Before starting assembly Before starting assembly read the safety instruction...

Page 11: ...to the functions lift lower open close retract or extend before the assembly is entirely completed 2 3 4 During initial commissioning Only operate the tail lift with its body If you operate the tail lift without its body there is a risk that the lifting cylinders will fall out if the lifting height is too high resulting in personal injury and material damage During initial commissioning of the PAL...

Page 12: ...Nm Socket wrench 4 6 4x screw clamps Peening tool Hand held electric drill 2 hand electric drill Spiral drill up to 14 mm diameter Crimping tool for cable lugs 16 mm 25 mm 35 mm Insulation stripper Side cutter TORX screwdrivers Mallet Impact wrenches size in mm 46 50 60 65 Locking pliers for external rings A2 Auxiliary equipment Assembly aid assembly device Stop bracket Marker Tape measure Trolley...

Page 13: ...ngs show the structure of the PALFINGER Tail Lifts tail lift and of the individual sub assemblies MBB C 1000 S C 3000 S MBB C 1000 LD C 2500 L MBB C 1500 SZ C 2500 LZ MBB C 1500 SK C 2500 SK MBB C 750 SPLD SPRD C 1000 SPL SPR MBB C 750 LD C 1000 L MBB C 1000 ML C 1500 ML MBB C 1000 ML PRO C 1500 ML PRO MBB C 750 S MBB C 750 LX MBB C 750 SX MBB C 500 LD C 750 L MBB C 750 SPL SPR MBB C 1500 LX C 200...

Page 14: ...ection 5 Platform support rod not included in scope of delivery 6 Tilt switch b13 tilt switch b15 7 Tilt switch b16 tilt switch b15 8 Foot operated switch option 9 Warning lamps option 10 Startup rail roll bar option 11 Useful load centre of gravity 12 Platform 13 Torsion frame 14 Lift cylinder 15 Tilt cylinder 16 Stand tube 17 Manual cable switch option 1 2 2 3 4 5 8 9 10 11 12 13 14 15 16 17 6 7...

Page 15: ... 3 Tail lift with bolted consoles and slide in unit 1 Welded console plates 2 Hydraulic unit 3 Underride protection 4 Tilt cylinder 5 Lift cylinder 6 Lift rocker 1 Bolted console plates 2 Hydraulic unit 3 Underride protection 4 Tilt cylinder 5 Lift cylinder 6 Lift rocker 1 2 3 4 5 6 1 2 3 4 5 6 ...

Page 16: ...4 5 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 1 Bolted console plates 2 Hydraulic unit 3 Underride protection 4 Tilt cylinder 5 Lift cylinder 6 Platform 7 Turning unit 1 2 3 4 5 6 7 ...

Page 17: ... been correctly delivered Have the general installation diagram and the attachment report attachment diagram been provided in accordance with your ordered PALFINGER Tail Lifts tail lift type Is the vehicle suitable for mounting the PALFINGER Tail Lifts tail lift Do the vehicle dimensions correspond to those of the PALFINGER Tail Lifts tail lift Is the operating voltage of the vehicle battery appro...

Page 18: ...red Has allowance been made for the space required for the optional grab handle 25 mm finger room between platform and handle 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 preparation of vehicle or vehicle chassis...

Page 19: ... the lifting mechanism for any offset rear lights the thickness of the vehicle s rear cross member and any cutouts required in the lower tail chassis To prepare the vehicle for installation of the PALFINGER Tail Lifts tail lift the following steps must be completed remove projecting parts of the vehicle see chapter 6 1 on page 20 make any necessary cutouts for the lifting mechanism and reinforce t...

Page 20: ...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 incompatible components ATTENTION Damage and loss of components If you do not safely store the removed components in a dry place they may be damaged or lost Remove the interfering components carefully from t...

Page 21: ...reate the cutouts according to the attachment mounting diagram and reinforce them Seal the blank body parts with rust protection and repaint them Observe the vehicle manufacturer s superstructure guidelines 6 3 Reinforcing rear cross member optional Your truck s rear cross member must be rated for your ordered type of PALFINGER Tail Lifts tail lift Your vehicle s rear cross member should be able t...

Page 22: ... instructions supplied Box bodies with doors To avoid damage to box body doors you must attach spacers and bridging profiles You must then abut the platform to the superstructure end with the bridging profile when the doors are open 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 Moun...

Page 23: ...allation aids on the vehicle chassis see chapter 7 1 1 on page 23 position lifting mechanism under the vehicle see chapter 7 1 2 on page 24 bolt lifting mechanism to installation aids see chapter 7 1 3 on page 25 position the stand tube see chapter 7 1 4 on page 26 fix lifting mechanism with console plates to vehicle chassis see chapter 7 1 5 on page 26 mount hydraulic unit see chapter 7 1 6 on pa...

Page 24: ...anism under the vehicle Raise the lifting mechanism with suitable lifting equipment such as a forklift truck or trolley jacks for example Carefully position the lifting mechanism under the vehicle Detach the cables and hoses and feed them through the openings provided in the vehicle chassis Carefully raise the lifting mechanism and move it into the installation position Maintain the installation p...

Page 25: ...sealing system is present to attach spacers to ensure correct spacing between the control rod and vehicle chassis Secure the lifting mechanism with screw clamps to the vehicle chassis Lay the cables and hoses under the vehicle chassis Bolt the lifting mechanism to the installation aid 1 and check the alignment to the vehicle body The control rod must be lie flush on both sides of the rear cross me...

Page 26: ...d The following console pates can be ordered from PALFINGER Tail Lifts welded consoles bolted consoles 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 ch...

Page 27: ...ter of drill holes Drill the holes in the console plates The hole pattern of the bearer can be used for this If there is no hole pattern on the bearer the bearer must be drilled through Bolt the console plates to the vehicle chassis In the process note the tightening torques in the general assembly diagram and in the table on page 28 ATTENTION Damage to the slide in unit during welding work If you...

Page 28: ...00 ML PRO C 750 SPLD SPRD 6 M14x1 5 190 Nm C 1000 S C 1000 SPL SPR C 1000 LD C 1000 L C 1500 L C 1500 ML PRO C 1500 S C 2000 S 10 M14x1 5 190 Nm C 1500 LX C 2000 LX C 1500 SZ C 2000 LZ C 1500 SK C 2000 SK C 2000 L C 2500 L C 2000 LK C 2000 LX PTG C 2500 S 12 10 M14x1 5 M16x1 5 190 Nm 310 Nm C 2500 SK C 2500 SD 14 M14x1 5 190 Nm C 3000 S NOTE Screws and nuts may only be used once If these are loose...

Page 29: ...e stand tube 1 Turn the hex nuts 5 on the bolts 3 and thus fix the console plate 2 and the U section 6 Align the two console plates corresponding to the frame width and pretighten the hex nuts NOTE We recommend installation of the bolted consoles to the vehicle chassis before positioning of the lifting mechanism under the vehicle optional 8 6 2 4 5 3 1 7 1 stand tube 2 console plate 3 Bolts 4 hook...

Page 30: ...attery cable is not directly connected to the battery and the ground runs over the vehicle chassis it may be necessary to fabri cate a ground cable from the delivered cable lugs and protective caps Cut off the required length of cable from the supplied battery cable Keep the ground cable 8 as short as possible and attach it to the ground screw provided on the stand tube Before lifting the platform...

Page 31: ...he vehicle If the cables and hoses are too long you must bundle them and fix them under the vehicle 7 1 7 Removing the installation aids Remove the pins between the control rods and the installation aids and carefully fold the control rods down Release the screw clamps with which the installation aids are fixed to the vehicle chassis Remove the installation aids from the vehicle chassis ATTENTION ...

Page 32: ...chanism see chapter 7 2 2 on page 33 mount auxiliary device see chapter 7 2 3 to page 33 position and fix platform see chapter7 2 4 on page 34 install lifting mechanism see chapter 7 2 5 on page 35 remove auxiliary device see chapter 7 2 6 on page 35 7 2 1 Positioning lifting mechanism under the vehicle Raise the lifting mechanism with suitable lifting equipment such as a trolley jack for example ...

Page 33: ...ght steel bearers of sufficient length on the load area between the control rod arms and vehicle body wall CAUTION Risk of falling equipment If you incorrectly position the auxiliary device or do not fix it correctly the lifting mechanism with the platform may fall and cause personal injury or material damage Make sure that the auxiliary device has a sufficient load bearing capacity to bear the li...

Page 34: ... that the control rod heads rest up against the rear wall apron Observe the relevant assembly diagram Fix the platform securely to the auxiliary device For this purpose use appropriately rated screw clamps and additionally secure the platform against falling with trestles for example Detach the cables and hoses and feed them through the openings provided in the vehicle chassis Carefully raise the ...

Page 35: ...chanism according to the type of console plates used see chapter 7 1 5 on page 26 For this purpose use the adjustment gauge indicated on the installation diagram Bolt the tilt cylinders to the platform see chapter 9 3 on page 44 7 2 6 Removing auxiliary device Release the screw clamps fixing the auxiliary device to the vehicle chassis Remove the auxiliary device from the vehicle chassis ...

Page 36: ...re required establish connection to vehicle battery see chapter 8 1 on page 36 install and connect optional control unit see chapter 8 2 on page 38 mount control panel holder see chapter 8 3 on page 38 connect optional hand cable switch see chapter 8 4 on page 39 connect optional remote control see chapter 8 4 on page 39 8 1 Establishing connection to vehicle battery Lay the plus battery cable to ...

Page 37: ...installed 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 attachments NOTE In order to disconnect the tail lift from the power supply in the event of a fault we recommend installing a battery disconnector ...

Page 38: ...the control unit to the driver s cab Select a suitable location on the dashboard in the driver s cab Establish an electrical connection as per the PALFINGER Tail Lifts circuit diagram Mount the control unit on the dashboard 8 3 Mounting the control panel holder Fix the control panel holder with screws or weld it in position as per the PALFINGER Tail Lifts assembly diagram NOTE Connection of the co...

Page 39: ...ch 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 from the marked position on the platform 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 ...

Page 40: ...e The receiver and the wireless remote control are pread justed so that they are immediately operational A detailed descrip tion is supplied with the wireless remote control NOTE If the manual cable switch is on the attachment this is not supplied with a socket but is connected via a junction box with the wire from the circuit board The manual cable switch is then fixed and cannot be unplugged The...

Page 41: ... control rod see chapter 9 2 on page 42 Bolting the platform to the first tilt cylinder see chapter 9 3 on page 44 adjust the tilt cylinder see chapter 9 4 on page 47 bolt the platform to the second tilt cylinder see chapter 9 5 on page 48 Connecting plug for foot operated switch and Warnfix see chapter 9 6 on page 48 install tilt sensor see chapter 9 7 on page 49 9 1 Moving up and positioning pla...

Page 42: ...until the platform is bolted to control rod and tilt cylinders 9 2 Bolting the platform to the control rod Make sure that the platform is in its final installation position Bolt the platform to the control rod Use the spacer discs supplied to align the platform centrally with the body NOTE On a type C 750 S tail lift with a 550 control rod you may only move the platform by one disc from the centre...

Page 43: ...ng 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 Observe the torque of 75 Nm ...

Page 44: ... the platform Inserting the air filter option Depending on the hydraulic unit manufacturer you will have remove the plug screw of the oil tank and replace with an air filter before you can bolt the platform to the first tilt cylinder A slide in unit is shown in the image The air filter is inserted in a similar way for turning box and universal units Open the sealing cap on the hydraulic unit and c...

Page 45: ...clamp and slide the bellows down Turn the rod end of the tilt cylinder on the piston rod as far as it will go clockwise Adjust the tilt cylinder length so that it possible to easily bolt the tilt cylinder to the platform NOTE To do this actuate the rotary switch for Open or Close at the same time holding the tilt sensor b15 or b16 with the cable pointing downwards not necessary with Basic controll...

Page 46: ...t 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 Observe the torque of 75 Nm Mount the floor roller and secure the pin with a snap ring Move the lifting mechanism via the lift cylinder to the upper stop Remove the lifting equipment Spacer discs ...

Page 47: ...sition To do this turn the piston rod with a wrench Repeat the adjustment process if required until the platform has reached the desired position 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 clip NOTE At the desired end position of the pla...

Page 48: ...r foot operated switch and Warnfix Connecting the plug for foot switch and Warnfix is necessary for tilt sensors b15 and b16 Detach the strain relief Pull the cables for the foot operated switch and the Warnfix from the platform Connect the plugs with the plugs that come from the control rod Make sure that colour coding of the plugs match Stow the connected cables again in the tailgate Reconnect t...

Page 49: ...s as shown on the right of the platform Feed the cables through the openings Bundle up cables that are too long and secure these with cable binders Connect the cables and pull them back to the right length Fix the sensor to the platform Observe the torque of 5 Nm Lay a loop for strain release Secure the cables with cable binders NOTE With a b15s only the tilt sensor has to be plugged into the mati...

Page 50: ... page 52 checking all screw connections see chapter 10 5 on page 53 attaching warning strips and type plate see chapter 10 6 on page 54 performing acceptance test as per test book see chapter 10 8 on page 56 10 1 Set tilt switch b13 Move the platform to the horizontal position as shown above approx 250 mm above the floor Release the screw on tilt switch b13 on the right torsion arm Adjust tilt swi...

Page 51: ... on ground Open and lower the platform until it sets down on the ground Check that the platform rests horizontally on the ground If the platform does not lie level release the screw on tilt switch b16 Adjust tilt switch b16 so that the platform rests level on the ground Retighten the screw on tilt switch b16 Observe the torque of 9 Nm NOTE This test only has to be performed if tilt switch b16 is p...

Page 52: ...rol mark on the oil tank is visible Check the display on the oil tank or dipstick to see if the display is within the prescribed marked range If necessary fill the oil level up to the marked area Slide the hydraulic unit back into the stand tube and fix it with the fixing screw Close the right cover of the stand tube Box universal or turning unit To check the oil level Lower the tail lift so that ...

Page 53: ...ift 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: ...il Lifts tail lift Clean and degrease the surface for the type plate at the bottom right of the platform Glue the supplied type plate to the platform Glue the test plaque on a prominent place 10 7 Adjusting the optional pressure switch of the hydraulic support If the hydraulic support raises the vehicle too high or the props do not reach the ground the pressure switch of the support can be ad just...

Page 55: ...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 If the desired shut off of the support is not provided repeat the adjustment ...

Page 56: ...commissioning in accordance with the test book Enter the required details in the test book Company Code Installation company Details of signatory It is essential that you enter the details on the operator and vehicle on page 3 as well as the form Confirmation by the installation firm on page 11 of the test book ...

Page 57: ...ments 6 F Foot operated switch Connecting plug 48 H Hydraulic circuit diagrams 59 I Installing control unit 38 tilt sensors 49 Installing lifting mechanism with installation aids 23 with platform 32 M Model line 13 P Personnel qualifications8 Preparing for installation 17 vehicle 19 S Safety instructions Before starting assembly 10 During assembly 11 general 10 Initial commissioning 11 scope of de...

Page 58: ...58 Index T Tail lift platform 16 standard 14 with bolted consoles 15 with welded consoles 15 Tools 12 Truck with box body 19 W Warnings Layout 9 ...

Page 59: ...uit diagrams 12 Hydraulic circuit diagrams 12 1 Standard tail lift with four cylinders 96 560 98 00 00 00 R2 R1 DBV1 M R5 P T B A S5 A B A A A B R4 R3 S4 S2 S1 S3 TILT CYLINDER LIFT CYLINDER TILT CYLINDER LIFT CYLINDER ...

Page 60: ...60 Hydraulic circuit diagrams 12 2 Standard Tail Lift With Soft Levelling KIPPZYL LIFT CYLINDER LIFT CYLINDER TILT LOCK TILT CYLINDER TILT CYLINDER ...

Page 61: ...61 Hydraulic circuit diagrams 12 3 Standard tail lift with two cylinders 97 510 98 00 00 00 R2 DBV1 M R5 P T B A S5 A A B R3 S2 S3 TILT CYLINDER LIFT CYLINDER ...

Page 62: ...s 12 4 Standard tail lift with hydraulic support 96 524 98 01 00 00 B A S9 B V A V S8 S7 B K A K A H A H A K B K B A DBV1 M R5 P T B A S5 A B A R1 R3 S1 S3 A B A R2 R4 S2 S4 TILT CYLINDER LIFT CYLINDER TILT CYLINDER LIFT CYLINDER ...

Page 63: ...63 Hydraulic circuit diagrams 12 5 Tail lifts with hydraulic support MBB C 750 L C 1000 L Support cylinder TILT CYL LIFT CYL Pressure switch S8 1 adjusted to 20 bar ...

Page 64: ...64 Hydraulic circuit diagrams 12 6 Standard tail lift with hydraulic under ride protection 99 514 98 01 00 00 3 LIFT CYLINDER TILT CYLINDER TILT CYLINDER LIFT CYLINDER ...

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Page 66: ...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 Gogolova 18 SK 85101 Bratislava Tel 421 252 636 611 Fax 421 252 636 612 mbbsk palfinger com www palfinger com PALFINGER Tail Lifts Ltd Gate House Fretherne Road Welwyn Garden City UK Herts AL8 6NS Tel 44 01707 325571 Fax 44 01707 327752 inforatcliff palfinger com www palfinger...