Palfinger PTV 33 User manual

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

PTV 35/44/55/66 Installation Manual
Document Part Number: 90-1121-100 / 21-680_90-00_01-00
ECN-M1571, Rev. 1.1, 05-17-21
Copyright © 2021 Palfinger Liftgates LLC.
All rights reserved.
Information in this document is subject to change 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 Order
[e-mail]
Technical Support
[e-mail]
15939 Piuma Ave.
Cerritos, CA 90703
Tel [phone]
Fax [phone]
572 Whitehead Road.
Trenton, NJ 08619
Tel [phone]
Fax [phone]

PTV 33/44/55/66 Installation Manual
Rev. 1.11
Table of Contents
1Manual Updates ........................................................................................................................ - 4 -
2Safety Information ....................................................................................................................- 5 -
3Important Information............................................................................................................... 6
4Tools For Installation................................................................................................................ 8
5Parts List................................................................................................................................... 9
6General View of Liftgate...........................................................................................................10
7Installation Dimension Sheets.................................................................................................12
8Installation Dimensions............................................................................................................14
8.1 Important Dimensions ...................................................................................................14
8.2 Installation Dimensions - Weld On-Liftgate...................................................................15
8.3 Installation Dimensions - Bolt-On Liftgate.....................................................................16
Installation Dimensions - Width Requirements............................................................................17
8.4 Strength Requirements .................................................................................................18
9Body 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 Preparation..................................................................................................................25
10.1 Liftgate Preparation.......................................................................................................25
11 Liftgate Mounting......................................................................................................................27
11.1 Mounting the Liftgate (Standard Installation).................................................................27
11.2 Liftgate Welding ............................................................................................................33
11.3 Bolt-On Liftgate Installation (Optional)...........................................................................37
11.3.1 Factory Installed Method .................................................................................37
11.3.2 Customer Installed Method..............................................................................39
12 Hydraulic Installation................................................................................................................42
12.1 Hydraulic Enclosure - Dimensions.................................................................................42
12.2 Hydraulic Enclosure –Hose Kits ...................................................................................42
12.3 Hydraulic Enclosure –Installation..................................................................................43

PTV 33/44/55/66 Installation Manual
Rev. 1.12
12.4 Hydraulic Connections ..................................................................................................44
12.4.1 Cab Shutoff Switch Installation (Optional)........................................................50
12.5 Hydraulic Schematic......................................................................................................52
12.6 Hydraulic Pump/Motor Overview...................................................................................53
12.7 Hydraulic Fluid ..............................................................................................................53
13 Electrical Installation................................................................................................................54
13.1 Auxiliary Batteries Installation........................................................................................55
13.4 Battery Wiring –Truck and Trailer.................................................................................56
13.5 Cable 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
13.11 Trailer to Tractor Ground Test.......................................................................................63
13.12 Tail Light Harness.........................................................................................................64
14 Lubrication................................................................................................................................65
15 Decal Placement .......................................................................................................................66
16 Cycle Test and Bleed the System............................................................................................69
16.1 Cycle Test and Bleed the hydraulic system, Standard Units..........................................69
16.2 Operating Instructions (Standard Units).........................................................................69
16.3 Dock Loading –Lowering Platform (Standard Unit).......................................................73
17 Final Inspection Check List......................................................................................................74

PTV 33/44/55/66 Installation Manual
Rev. 1.13
Company Information:
Company Name:
Advisor 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 [phone]
Fax [phone]
572 Whitehead Road.
Trenton, NJ 08619
Tel [phone]
Fax [phone]

PTV 33/44/55/66 Installation Manual
Rev. 1.14
1 Manual Updates
Revision
Description
v1.0
•Initial Release

PTV 33/44/55/66 Installation Manual
Rev. 1.15
2 Safety Information
This manual follows the Guidelines set forth in “ANSI Z535.4-2007” for alerting you to possible hazards and
their potential severity.
This is the safety alert symbol. It is used to alert you to potential personal injury hazards. Obey all safety
messages that follow this symbol to avoid possible injury or death.
! DANGER indicates an imminently hazardous situation which, if not avoided, will result 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, if not avoided, may result minor or moderate
injury.
CAUTION without the safety alert symbol is used to address practices not related to personal injury. (In this
manual we use it to alert you to potentially hazardous situation which, if not avoided, may result in property
damage.)
NOTICE without the safety alert symbol is used to address practices not related to personal injury. (In this
manual we use it to alert you to special instructions, steps, or procedures.)

PTV 35/44/55/66 Installation Manual
Rev. 1.16
3 Important Information
Before Getting Started
“READ FIRST”
The PTV is an industrial hydraulic lifting device. Performance and reliability are closely related to
proper installation, battery cable connections, and grounding. All grounding surfaces MUST be
cleaned, prepared to bare metal, free of paint, undercoating, dirt, grease, and sealed per this manual.
“Cut to size” cables MUST be properly crimped and sealed as factory supplied. All connections MUST
be dressed with dielectric grease or equivalent sealer.
•Read and understand the “Installation Manual” and “Owner’s Manual” in their entirety before starting your
Installation.
•Refer to the truck manufacturer’s instructions 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 other person underneath the liftgate at
any point during the installation, unless the liftgate is fully welded AND all moving components are safely
secured.
•All welding should be performed by qualified personnel per AWS standards.
•Always ground closest to your welding point to prevent arcing through moving parts or electrical parts.
•Contact PALFINGER Liftgates for Special Installations not covered in this Installation Manual.
•Do not paint cylinder shafts or nylon bearings (Use non-chlorinated brake cleaner to remove over spray)
•Final Check-Off-Sheet at rear of this manual MUST be filled out and kept in your records for future
reference.
•Refer to owner’s manual for operation and maintenance information.

PTV 35/44/55/66 Installation Manual
Rev. 1.17
Improper operation of this liftgate may result in severe personal injury or death. DO NOT operate
unless you have been properly instructed, have read and are familiar with the procedures in this
manual. This manual has been designed to illustrate the steps needed for the basic installation of the
PTV liftgate. It also provides safety information and simple preventive maintenance tips.
This manual is not intended for use as a repair or troubleshooting guide. Repairs should be performed
by a PALFINGER Liftgates Authorized Service Center.
This Manual has been designed for use in conjunction with 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 tag on the liftgate (Located on Left Side Column- as shown below)
Cerritos, CA.
Trenton, N.J.
[phone]
Model Serial No. Date
ILD
ML680-VL-A
0123456789
OR
Serial
Number
Location
2) Ask your employer or lessor.
3) Call your PALFINGER Liftgates Authorized Service Center for assistance.
4) Call PALFINGER Liftgates for assistance in the USA at 888-774-5844. You can also contact PALFINGER
Liftgates by fax [phone] or on the internet- www.palfinger.com
For technical support, contact PALFINGER Liftgates or an authorized PALFINGER service center.
www.palfinger.com
Replacement manuals are available at https://www.palfinger.com/en-us/products/liftgates

PTV 35/44/55/66 Installation Manual
Rev. 1.18
4 Tools For Installation
SAE & Metric Wrench
Set
Basic Screwdrivers
Assorted Pliers
Wire Crimp Pliers
Digital Multi-Meter
Snap Ring Pliers
Hammer
SAE & Metric Allen key Set
½” Impact & Sockets
SAE & Metric Socket Set
Assorted Drill Bits
Floor Jack or Equivalent
Sm. To Med. Bottle
Jack
Forklift or Overhead Hoist
Handheld Grinder
Paint Gun & Accessories
Pry Bar
3/8 Drill Motor
Grease Gun
Heat Gun or Equivalent
Min.250A Welder
Cutting Torch or Equivalent
Framing Square
Measuring Tape

PTV 35/44/55/66 Installation Manual
Rev. 1.19
5 Parts List
Installation of the parts listed below can be found throughout the installation manual.
All of the small parts are bagged, boxed or attached inside the Hydraulic Enclosure.
Nylon Strap Battery Kit: 99-7520-001
Nylon Hold Down, 1 pc
Hex Head Cap Screw, 3/8"-16x10", 4 pcs
Washer, Flat, 3/8" USS, Zinc; 8pcs
NylockNut, 3/8"-16; 4pcs
Electric Components: 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, 11", 3/8" Lugs, 2GA, Red, 2 pc
KET06062A; Bus Bar, Red; 2 pcs
KET05916A; Bus Bar, Black; 2 pcs
EM 781; Nut, Serrated, 3/8"-16, SS; 6 pcs
Hydraulic Fittings Kit: 80-1121-100
Elbow, 90°, 1/4", JICFemale - 1/4", JICMale, 2 pcs
Elbow, 90°, 3/8", JICFemale - 3/8", JICMale, 2 pcs
3 ft. Hose Kit: 80-1121-001
1/4" Hoses, 3 ft (36"), 2 pcs
3/8" Hoses, 3 ft (36"), 2 pcs
Decal Base Kit: 85-1121-010
Decal Base Kit; 10 pcs
2X
1/4"
2X
3/8"
2X
1/4"
2X
3/8"

PTV 35/44/55/66 Installation Manual
Rev. 1.110
6 General View of Liftgate
Tail Light
Left Side
Column
UHMWDock
Bumpers
Chain
Arms
Support
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 platformramps. Same options are available for aluminum platforms.
Platform
Tip Section
Platform
Main Section
Toggle Switch
(Not Shown)

PTV 35/44/55/66 Installation Manual
Rev. 1.111
Control
Board
Primary
Pump & Motor
Battery
Compartment
Master
Shutoff
Switch
Shipping
Brace
Enclosure
Cover
Carrier
Frame
Battery
Voltage
Gauge
Manual
Reset
Circuit
Breakers
Auxiliary
Remote
Control
Cable
Entry
Ports
Hydraulic Enclosure: Dual Pump Configuration
Hydraulic Enclosure: Single Pump Configuration
Secondary
Pump & Motor
Control
Board
Primary
Pump & Motor
Battery
Compartment
Master
Shutoff
Switch
Shipping
Brace
Enclosure
Cover
Carrier
Frame
Battery
Voltage
Gauge
Manual
Reset
Circuit
Breaker
Auxiliary
Remote
Control
Cable
Entry
Ports
Security
Lock Hole
Security
Lock Hole

PTV 35/44/55/66 Installation Manual
Rev. 1.112
7 Installation Dimension Sheets
A= Bedheight:.....................................________ Loaded Bedheight:.....................................________
B = Top of floor to bottom of frame:.............................................................................................________
C = Rear sill height:.......................................................................................................................________
D = Spring hanger to end of body (if applicable):......................................................................________
E =Air bag suspension to end of body (if applicable):..............................................................________
F = Tire to end of vehicle body:....................................................................................................________
G = Gas tank to end of body (if applicable):................................................................................________
H = Fuel filler hole to end of body (if applicable):......................................................................________
I = Bottom of frame to bottom of gas tank (if applicable):........................................................________
J = Top of floor to bottom of sliding walk ramp (if applicable):.................................................________
K = Frame Width: Width of chassis frame:..................................................................................________
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 applicable)
Flip-Up
Roll-Up
Swing
Other (specify)________________
Truck Specifications:
Manufacturer: (ex. Hino)
GVWR: (ex. 68,000 lbs)
Length: (ex. 53ft)
Width: (96", 102")
Truck Chassis Dimension Sheet
Liftgates Information:
Model
Capacity
PlatformSize
PlatformMaterial
90-9813-003_b
Notes:
Side View of Truck Rear View of Truck
Walk Ramp (if applicable)
A
B
C
D
E
F
G
J
H
IK
L
Customer Information
Quote#/SO#:____________________________________________________
Company:______________________________________________________
Phone:_________________________________________________________
Email: _________________________@______________________________

PTV 35/44/55/66 Installation Manual
Rev. 1.113
A= Bedheight: Top of trailer floor to level ground (with airbags up):........................................................................________
B = Top of floor to bottomof trailer cross member:.....................................................................................................________
C = Rearsill height (Top of floor to bottom of buckplate):If Stepped sill complete M,N; If Taperedsill complete O, P.
D = Crossmember height:...............................................................................................................................................________
.
E = Tire to end of vehicle body:......................................................................................................................................________
F = Bogie to end of vehicle body................................................________ Sliding Suspension? Yes________ No________
IfYescomplete G, H, I, K, and Ldimensions
G = Inside horizontal width of sliding suspension angles:.........................................................................................________
H = Diameter of sliding suspension holes:...................................................................................................................________
.
I = Hole spacing:..............................................................................................................................................................________
J =Bottomof crossmembers to bottomof slidingramp box, if applicable:.............................................................________
K = Rearsill faceto first sliderhole:.............................................................................................................................________
L = Top of floor, where liftgate platform will meet floor, to the center of the trailer slider holes:............................________
X = Eyebrow depth:.........................................................................................................................................................________
Z = Top of floor, where the liftgate platformwill meet the top of the eyebrow:.........................................................________
Customer Information
Quote#/SO#:____________________________________________________
Company:______________________________________________________
Phone:_________________________________________________________
Email: _________________________@______________________________
Trailer Information
Trailer Dimensions
Type of Body (check applicable)
Van
Flatbed
Reefer
Other (specify)____________
Type of Rear Door (check applicable)
Flip-Up
Roll-Up
Swing
Other (specify)________________
Trailer Specifications:
Manufacturer: (ex. Utility)
GVWR: (ex. 68,000 lbs)
Length: (ex. 53ft)
Width: (96", 102")
Trailer Chassis Dimension Sheet
Liftgates Information:
Model:
Capacity:
PlatformSize:
PlatformMaterial:
90-9813-002_b
Flush Stepped Tapered
M = ________
N = ________
O = ________
P = ________
A
BC
D
EF
G
Side View of Trailer Rear View of Trailer
X
Z
LK
ø
HI
Walk Ramp (if applicable)
J
M
N
O
P
Notes:
C
C = ________

PTV 35/44/55/66 Installation Manual
Rev. 1.114
8 Installation Dimensions
8.1 Important Dimensions
Minimum Bed Height dimensions are ALWAYS MAXIMUM LOADED TRUCK.
Maximum Bed Height dimensions are ALWAYS DRY UNLOADED TRUCK.
Ensure that the truck body or trailer rear door does not interfere with installation or operation of the
PTV series liftgates.
The PTV series cannot 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 from the rear sill of the truck or
trailer. Installers are advised to use a sub-frame or flush sills as required. Removing gussets,
stiffeners, light rings, or other such support structures may VOID your truck/trailer warranty.
Call tech support before starting the installation if you have any questions or concerns on mounting dimensions
or procedures 888-774-5844.

PTV 35/44/55/66 Installation Manual
Rev. 1.115
8.2 Installation Dimensions - Weld On-Liftgate
1. Measure Floor Height: Measure the floor height of your truck or trailer and determine clearance
requirements for your liftgate platform size.
2. Verify Compatibility: Reference the compatibility table below to ensure that 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.
Max.
Min.
Max.
PTV BG
42”+16” ARR
80“
86“
46“
56“
34“
56“
PTV
60”+12” Fixed Ramp
80“
86“
32“
56“
34“
56“
PTV
60”+16” ARR
80“
86“
32“
56“
34“
56“
PTV
72”+12” Fixed Ramp
80“
86“
38“
56“
34“
56“
PTV
72”+16” ARR
80“
86“
38“
56“
34“
56“
PTV
84”+16’ ARR
80“
86“
44“
56“
34“
56“
ARR = Aluminum Retention Ramp; BG = Bottle Gas
86-1/4"
15-1/8"
56" MAX
12-1/4"
3-1/2"
75-1/4"
11-1/4"

PTV 35/44/55/66 Installation Manual
Rev. 1.116
8.3 Installation Dimensions - Bolt-On Liftgate
1. Measure Floor Height: Measure the floor height of your truck or trailer and determine clearance
requirements for your liftgate platform size.
2. Verify Compatibility: Reference the compatibility table below to ensure that 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.
Max.
Min.
Max.
PTV BG
42”+16” ARR
80“
86“
46“
56“
34“
56“
PTV
60”+12” Fixed Ramp
80“
86“
32“
56“
34“
56“
PTV
60”+16” ARR
80“
86“
32“
56“
34“
56“
PTV
72”+12” Fixed Ramp
80“
86“
38“
56“
34“
56“
PTV
72”+16” ARR
80“
86“
38“
56“
34“
56“
PTV
84”+16’ ARR
80“
86“
44“
56“
34“
56“
ARR = Aluminum Retention Ramp; BG = Bottle Gas
13"
14-3/4"
5-1/4"
15-1/8"
75-1/4"
84-1/4"
56" MAX

PTV 35/44/55/66 Installation Manual
Rev. 1.117
Installation Dimensions - Width Requirements
Reference the chart below to determine the liftgate width dimensions. Ensure that your vehicle meets these
requirements. The PTV series liftgate is offered in two widths for 96” and 102” wide bodies.
Nominal
Truck or Trailer
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"
95-7/16"
90-5/16"
75-3/16"
74-9/16"
84-3/8"
15-1/8"
Nominal
Truck or Trailer
Width
Outside
Column Dim.
Inside Column
Dim.
Inside Platform
Chain Plate
Overall
Outside Dim.
Overall Liftgate Dim.
H“xW“
102” Wide Body
100-7/16“
90”-3/8“
84-5/8“
101-7/16“
90-5/16“ x 101-7/16“
100-7/16"
84-5/8"
90-5/16"
75-3/16"
101-7/16"
80-9/16"
90-3/8"
15-1/8"

PTV 35/44/55/66 Installation Manual
Rev. 1.118
Z
Z
Y
Y
X
X
8.4 Strength Requirements
Reference the chart below for side wall requirements. Ensure that the body side wall, corner 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
PTV 66
X = Side Wall Tension
1900 lbs.
2400 lbs.
2950 lbs.
3500 lbs.
Y = Side Wall Compression
1900 lbs.
2400 lbs.
2950 lbs.
3500 lbs.
Z = Side Wall Shear
2700 lbs.
3100 lbs.
3800 lbs.
4300 lbs.