Palfinger V Series User manual

DOC: 4835-118409 DATE: 23.06.2020
Please ensure that you fully read and understand this manual
before you operate the lift

DOC: 4835-118409 DATE: 23.06.2020
In order to comply with CE Marking Regulations, it is
mandatory that the post-installation test procedure described
in the Load Testing section is carried out and the test
certificate is completed to validate the CE Mark. This test
certificate must then be returned to PALFINGER in order to
allow the Company to create an EC Declaration of
Conformance for the lift.
CE Marking Regulations are UK Criminal Law.
“ORIGINAL INSTRUCTIONS”

TABLE OF CONTENTS
Introduction...........................................................................................................................4
General .............................................................................................................................4
Modifications .....................................................................................................................4
Location Diagram..................................................................................................................4
Fitting....................................................................................................................................5
General .............................................................................................................................5
Unpack Equipment............................................................................................................5
Work Light.........................................................................................................................5
Checks before Fitting.........................................................................................................5
BOX BODY .......................................................................................................................6
DROPSIDE BODY............................................................................................................6
UNDERUN BAR................................................................................................................7
LITTING ............................................................................................................................8
ADJUST POSITION OF LIFT ............................................................................................9
WELDING .......................................................................................................................10
FULLY WELD COLUMNS TO VEHICLE.........................................................................11
BOLTED FRAME ............................................................................................................12
UNDER-RUN BAR AND LIGHTS........................................................................................14
UNDER-RUN BAR ..........................................................................................................14
FITTING DROPPERS .....................................................................................................16
LOCATION OF LIGHTS..................................................................................................18
ELECTRICAL INSTALLATION............................................................................................19
FITTING MAIN FUSE ASSEMBLY..................................................................................20
CAB SWITCH..................................................................................................................21
INTERNAL SWITCH........................................................................................................21
POWER PACK WIRING..................................................................................................22

1
FILL SYSTEM WITH HYDRAULIC OIL ...........................................................................22
LUBRICATE CHAINS......................................................................................................22
LABELS LAYOUT ...........................................................................................................23
DEMARKATION..............................................................................................................24
FLOOR HEIGHT .............................................................................................................25
CHAIN ADJUSTMENT....................................................................................................25
ALLOWABLE PROJECTIONS ........................................................................................25
REMOVAL.......................................................................................................................25
SCHEMATIC HYDRAULIC CIRCUIT..................................................................................26
ELECTRICAL CIRCUIT DIAGRAM.....................................................................................27
REVISIONS........................................................................................................................28

2

3
Heavy Duty Springs
The products covered by this handbook include one or more heavy duty springs which from
time to time during the operation of the lift store considerable levels of energy.
Such springs include:
•Torsion bars
•Torsion springs
•Helical springs
•Gas springs
Heavy duty springs are typically used in counter-balanced platforms and platform
extensions, and in conjunction with single-acting hydraulic cylinders.
Special care must be taken when:
•Fitting
•Servicing
•Repairing
•Dismantling
Lifts incorporating these springs or the springs themselves.
Before carrying out work on the lift, precautions should be taken to:
1. Read the Fitting and Service manuals as appropriate.
2. Ensure that the work is supervised by a competent engineer.
3. Ensure bystanders are not exposed to risk.
4. Use adequate protective clothing.
5. Secure movable parts, e.g. platform and runners.
6. Carefully relax spring elements before attempting their removal or adjustment.
7. Use special tools if necessary - for example, to pre-compress gas springs before
installation.
If any doubt exists regarding the safe working practices involved with heavy duty springs,
consult the Customer Service Department of Plafinger Tail Lifts Ltd before proceeding with
the work.
Warning: Spring elements store energy and are potentially dangerous. Incorrect
installation, use, adjustment or removal may result in serious injury.

4
Introduction
General
This publication contains the information required to fit or install the Quickfit “V” Series
Models to a suitable vehicle.
If any doubt exists as to the vehicle's suitability for having this type of lift fitted, the installer
should contact the nearest PALFINGER Tail Lifts Ltd factory who will advise the installer on
the suitability of his application.
Modifications
If it is desired to make a modification to the lift, or to the manner of its fitting, PALFINGER
Tail Lifts Ltd. are prepared to consider advising on the suitability of such modification
provided that such request is made in writing to the Engineering Department before the
modification or departure from fitting instructions is carried out.
If PALFINGER Tail Lifts Ltd. approves such modification or departure from fitting instructions
they will give their written authorisation which shall be retained by the person in receipt of
such written approval.
All liability under the provision of the Consumer Protection Act 1987 shall be that of a
person, firm or company responsible for any unauthorised modification or departure of fitting
instructions and such liability shall include a complete indemnity to PALFINGER Tail Lifts
Ltd. against any claim being made by or on behalf of the person suffering such loss or
damage.
Location Diagram
View of Lift
1. Column
2. Runner
3. Platform
4. Platform Catch
5. Stowlock
6. Top Flap (RQR518 only)

5
Fitting
General
The instructions assume that the rear frame is constructed of steel.
If it is of aluminium or other, steel strips should be bolted to the rear frame so that the lift can
be welded to these.
If there is any doubt concerning the strength of the rear frame to support the lift, suitable
reinforcing must be fitted.
Where the lift is to be fitted to a dropside body specific fitting kits are available from Palfinger
Tail Lifts UK or where these are not available bracing for the top and bottom of the columns
will be required as well as a the construction of a suitable mounting frame.
Unpack Equipment
Unpack the lift and check for possible damage in transit.
Check that the kit contents are as stated on the packing list.
Work Light
A work light is available from PALFINGER Tail Lifts Ltd for installation if requested.
Checks before Fitting
All the requirements specified in the relevant chassis manufacturer's Body Builders
Handbook are complied with for this vehicle/tail lift combination.
The vehicle has a box body with a flat back. (Packing may be used to overcome minor
projections such as rivets or bolt heads.)
The rear closure is roller shutter or special door hinges. (Palfinger Tail Lift do not
recomented to use doors for the rear closure with this lift.)
The rear frame has adequate strength.
The rear frame is steel of adequate strength.
There are no projections from the vehicle rear below floor level.
Some projections are allowable, refer to Appendix 1.
Chassis is clear for mounting drop arms. (If fitted)
Does the spare wheel need re-sitting.
After fitting, vehicle rear lights will conform to Road Traffic Regulations.

6
BOX BODY
500kg lifts fitted to a standard 3.5 ton vehicle
would not normally require body work
bracing but lifts of 750kg and 1000kg will
require diagonal braces from the vehicle
chassis/ body.
DROPSIDE BODY
Where the lift is to be fitted to a dropside
body specific fitting kits are available from
Palfinger Tail Lifts UK or where these are not
available bracing for the top and bottom of
the columns will be required as well as a the
construction of a suitable mounting frame,
example shown below.

7
UNDERUN BAR
Vehicles over 3.5 ton that require a underrun bar (Refer Underun section of this manual)

8
LITTING
Raise Lift to Floor Level
Position the lift so that it is central to vehicle body.
Position suitable slings, chains or forks of a forklift on the transit strut at the points shown.
Raise the lift so that top of beam is level with the vehicle floor using a crane, hoist or forklift.
Position the lift so that it is central to vehicle body.
Position suitable slings, chains or forks of a forklift on the transit strut at the points shown.
Raise the lift so that top of beam is level with the vehicle floor using a crane, hoist or forklift.

9
ADJUST POSITION OF LIFT
Adjust the height of the lift until the beam is
level with floor.
Column ground clearance for when under-
run bar is to be installed should be
approximately 430mm (maximum 550mm).
If necessary, cut bottom of columns,
ensuring all burrs are removed from inside
faces of column.
Adjust the lift so that it is central to body.
Clamp the lift to the rear frame.
V series attachment (welded)
To avoid damage to the plastic runner slide pads, do not weld in area 'A' (800mm
from the bottom of the runner).

10
WELDING
To avoid the danger of fire, heat and electronic damage when welding,
disconnect the vehicle battery.
Always connect earthing lead directly to component being welded. Do not earth through
hydraulic hoses or pipework.
Protect the power pack, hoses, bearings and wiring from heat and weld splatter.
WELDING FRAME
Tack welds the lift to the vehicle rear frame.
The tack welds must be of adequate
strength to support the full weight of the lift.
Do not fully weld the columns prior to
lowering the runners to the ground or
damage to the rear wear pads will result
If the lift is galvanised or fully painted, then
clamp to rear frame. Do not weld. Ensure
clamps are adequate to support the full
weight of the lift.

11
FULLY WELD COLUMNS TO VEHICLE
(For unpainted steel)
Using 5mm fillet welds of 100mm in length,
weld columns to vehicle rear frame. Welds
to be on both sides of each column.
Allow the welds to cool, lower platform to
ground and complete welds.
To avoid damage to the plastic runner slide pads do not weld temporarily in
area 'A'.

12
BOLTED FRAME
THE LIFT CAN BE BOLTED TO LIFT INSTEAD OF WELDED IF REQUIRED.
This is normally done where the lift frame is galvanised, the vehicles rear frame is stainless
steel or the customer specifies.
C/sunk head screws are supplied for this purpose.
ONLY USE BOLTS SUPPLIED WITH LIFT
STANDARD HEAD BOLTS WILL DAMAGE THE WEAR PADS.
With the lift in position, put suitable rags into the column above the runners to prevent swarf
dropping down into the LSD mechanism.
Mark the centres of the exposed mounting holes at the top of the columns on to the rear
frame.
Drill Ø8.5 holes through the rear frame.
Fit the screws, washers and nylon nuts supplied.
Use a hex key to stop the screw from turning.
Tighten nut with spanner to a torque –see table below.
Remove rags and swarf.
Complete installation of power pack and wiring. Then lower lift platform to expose remaining
mounting holes.

13
WARNING: DO NOT PUT ANY LOAD ON THE LIFT UNTIL ALL THE
MOUNTING BOLTS ARE IN PLACE.
Put clean rags into the columns above the runners as before.
Drill and fit fixings as before.
If the screws are used without nuts, the rear frame should be drilled tapping size - Ø6.8 and
the holes tapped M8 x 1.25 pitch.
Ensure that the rear frame thickness and material type are adequate.
Ensure threads are clean before using Loctite.
Ensure thread does not bottom out before the screw head is fully home.
Remove rags and swarf upon completion.
NOTE: Where the columns are bolted to timber pillars, fit washer plates under self l
locking nuts. Fit long washer plates where pillars are of aluminium to prevent
being localised in bolt positions.

14
UNDER-RUN BAR AND LIGHTS
It is the installer’s responsibility to ensure the under-run bar complies with the
under-run bar regulations.
It is the installer’s responsibility to ensure that the vehicle lights comply with
the lighting regulations with the tail lift fitted.
UNDER-RUN BAR
1.1. If the lift is supplied without an under-run bar fitted:-
a. Check the vehicle is exempt from the under-run bar regulations, less than 3.5
tonnes G.V.W.
b. Fit the under-run bar, supplied loose, to the lift.
c. Ensure that the vehicle under-run bar (supplied by the manufacturer or
bodybuilder) is compatible with the lift mounting, especially the support of the
column ends.
1.2. If supplied loose, attach the under-run bar to the columns using tack welds, clamps
or bolts as required.
1.3. Ensure the under-run bar is parallel to the vehicle floor.
1.4. Whatever under-run bar is fitted, ensure the height of the underside is 550mm
minimum above ground level, with the vehicle unladen.
1.5. If the height is below 550mm, reposition the under-run bar.
1.6. Attach the under-run bar to the chassis with brackets or drop arms strong enough
to take the weight of the loaded lift and the horizontal forces specified in the
under-run bar regulations.
1.7. Drop arms can be made from RHS including the 60 x 60 x 5mm material from the
transport trolleys and the mounting plates supplied in the fitting kit, welded together.
Alternatively, suitable brackets or drop arms can be made by the
installer/bodybuilder or supplied to order by PALFINGER Ltd.
Short drop arms or brackets may not require stays.
Drop arms or brackets should be attached to the chassis using nuts and bolts.
Do not drill holes through chassis webs within 30mm of a flange.
Do not drill holes through flanges.

15
Observe chassis manufacturer’s technical requirements
1.8. Stays from the ends of the under-run bar to either the raves or the chassis can be
fitted. Use the brackets supplied in the fitting kit with suitable lengths of 50 x 50 x 3
RHS. (The transport cross tube on Quickfits can be used or material supplied to
order with the lift.

16
FITTING DROPPERS
•Position the droppers on either side
of the chassis ensuring that they are
vertical. Ensure that the flanges of
the dropper are up against the plates
which come welded to the under run
bar (See Figure 1) The droppers are
designed for a range of vehicle floor
heights. If desired they can be
shortened by removing material from
the bottom of the dropper. When
satisfied that the droppers are
positioned correctly mark the chassis
using the pre-drilled holes in the
dropper and drill the chassis.
Assemble the droppers to the chassis
using the 12 off - M16 x 40 bolts
provided. With droppers in position
drill through the under run bar plates
and dropper flanges and secure with
4 off - M12 bolts provided.
Figure 1
Torque settings for:
M16 x 40 = 315 Nm
M12 x 40 = 85 Nm
•Select the appropriate position for the
horizontal braces. Bolt to the droppers
with the 4 off - M12 bolts supplied. To fit
the dropper to the chassis follow the
sequence detailed in the section ‘Fitting
Drop arms When attaching the brace to
the under run bar drill through the under
run bar plates and brace end plate and
secure with 4 off - M12 bolts provided
(See Figure 3) You must ensure the bolt
is positioned centrally through the brace
end plate. (See Figure 2)
Figure 2