SAFE-TECH Palift MK3 User manual

User’s Manual
Palift MK3 Manual
How to install, Use and Maintain
Version no: A
December 2016

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Contents
1.0 Introduction ........................................................................................................................ 4
1.1 Disclaimer ............................................................................................................................ 4
1.2 Copyright © 2016 ................................................................................................................. 4
1.3 Owner’s Responsibility ......................................................................................................... 5
2.0 Safety .................................................................................................................................. 5
3.0 Installing the Palift ............................................................................................................. 5
3.1 Lifting and Handling.............................................................................................................. 5
3.2 Transit Damage .................................................................................................................... 6
3.3 Installing the Springs ............................................................................................................ 6
3.4 Installing the Palift Mobility Kit ............................................................................................ 10
3.5 Location of the Palift ........................................................................................................... 12
4.0 Operational Restrictions .................................................................................................. 13
4.1 Availability of a Forklift ........................................................................................................ 13
4.2 Variation in Density of the Load .......................................................................................... 13
4.3 Layering of the Load........................................................................................................... 13
4.4 Rotating the Turntable ........................................................................................................ 13
4.5 Relocation of the Palift ....................................................................................................... 14
4.6 Load Capacity .................................................................................................................... 14
5.0 Operating the Palift .......................................................................................................... 14
5.1 Basic Operation .................................................................................................................. 14
5.2 Spring Selection ................................................................................................................. 14
5.3 Spring Selection Chart ....................................................................................................... 15
5.4 Changing the Springs ......................................................................................................... 16
6.0 Other Features .................................................................................................................. 16
7.0 Maintenance ..................................................................................................................... 17
8.0 Warranty ........................................................................................................................... 17
9.0 Safetech Divisions ........................................................................................................... 18
10.0 Hazard Identification, Risk Assessment & Control for Palift......................................... 19
10.1 Crushing and Shearing Injuries as a Consequence of Pinch Points ................................... 19
10.2 Crushing and Shearing Injuries as a Consequence of Pinch Points (Turntable) ................. 19
10.3 Crush Injuries due to Uncontrolled Descent ....................................................................... 19
10.4 Crushing by Falling Palift or Load ....................................................................................... 20
10.5 Blow from Moving Palift ...................................................................................................... 20
10.6 Descent Due to Spring Breaking ........................................................................................ 20
10.7 Descent Due to Spring Buckling ......................................................................................... 21
10.8 Collision (Mobility Kit only) .................................................................................................. 21
11.0 Trouble Shooting ............................................................................................................. 22
12.0 Identification and Spare Parts ......................................................................................... 23
12.1 Static-Base Square-top Palift (PST3) ................................................................................. 23
12.2 Static Base Turntable-Top Palift (PTG3) ............................................................................ 25
12.3 Palift Mobile Dolly kit (PMBD) ............................................................................................. 28

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1.0 Introduction
Palift is an Australian invention that makes manual loading and unloading of pallets safer, faster and
easier. Palift keeps the active layer of the load at or above waist height, eliminating bending and
lifting. It is highly effective at reducing the risk of back strain and back injury, the most common of
all workplace injuries (1994, Worksafe Australia
1
). Palift is now used worldwide.
Palift is a spring and scissor mechanism, simple, easy to use and requiring no maintenance.
Different springs are used depending on the height and weight of the load. The Palift incorporates a
shock absorber, which prevents any bouncing as the pallet is loaded.
Palift has a built-in turntable for operators to rotate the load. This eliminates stretching or walking
around the load.
Palift can be relocated using a mobility kit, forklift or pallet truck.
Read this manual before installing or using the Palift.
For assistance contact your Palift agent.
Post: Safetech Pty Ltd
PO Box 360
MOE VIC 3825
Phone: [phone]
Fax: [phone]
1.1 Disclaimer
Although every effort is made to ensure accuracy, currency and completeness of the information
contained in this manual, Safetech does not guarantee, warrant, represent or undertake that the
information is correct, accurate or current.
Safetech is not liable for any loss, claim, cost or expense of any kind arising in any way whatsoever
from the information contained in this manual.
1.2 Copyright © 2016
Safetech of 39-45 Della Torre Road, Moe Victoria, 3825, all rights reserved.
No part of this document may be reproduced or utilised in any means, by any means, electronic or
mechanical, including photocopying, recordings or any information storage or retrieval system,
without the express permission from Safetech.
1
Worksafe Australia (1994), The Compendium for Worker's Compensation Statistics 1991/92: Australian Government Publishing
Services.

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1.3 Owner’s Responsibility
To ensure both your safety and the safety of others, and the continued effective operation of your
Safetech Palift, your responsibilities are as follows:
 Before operating the Palift, please read and ensure you understand both the safety
instructions and the operating instructions.
 If you do not fully understand these instructions, contact either Safetech or an authorised
Safetech agent for clarification before operating your Palift.
 The Owner must review the Risk Assessment in this manual.
 Please Note: That in the Risk Assessment a number of items have been flagged as
Completed? = No. The Owner must include these hazards in their own operational risk
assessment and ensure that action is taken to address the hazard.
 The owner is responsible to ensure all operators have been adequately trained on the
safe operation of the Palift.
 The owner is responsible to ensure that a risk assessment on the Palift in their operating
environment is done.
2.0 Safety
This manual identifies hazards which may occur in the use of the Palift. It provides instructions or
precautions which should be taken to avoid or minimise these hazards. Safetech uses the following
system of identifying the severity of the hazards associated with its products:
"Danger” Immediate hazard which will result in severe personal injury or death.
"Warning" Hazardous or unsafe practice which could result in severe personal injury or death.
"Caution” Hazardous or unsafe practice which could result in minor personal injury or property
damage.
3.0 Installing the Palift
3.1 Lifting and Handling
Remove the Palift from the shipping pallet:
Cut strapping and remove all packaging.
The Palift has fork tyne sockets in the base frame for relocation by forklift. Alternatively the Palift can
be transported from the underside of the top frame

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Caution: When lifting the Palift from the underside of the top frame, the Palift will extend as it is
raised. Ensure that the Palift is fully extended and clear of the shipping pallet before
driving the forklift.
Figure 1
3.2 Transit Damage
Check Palift for transit damage.
Ensure that circlips and fasteners have not dislodged
3.3 Installing the Springs
Spring installation is best performed by two people.
Refer to Figures 2 to 7:
If the Palift incorporates a turntable, lift off the rotating ring and remove the plastic cover sheet.
(Figure 2)

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Figure 2
Open one hinged spring cap by squeezing the red spring loaded locking tabs together to unlock the
spring cap.
Raise the handle and open the spring cap. (Figure 3)
Spring Cap locks engaged
Spring cap locks disengaged

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Figure 3
Place one of the coil springs in the lower spring cap. (Figure 4)
Figure 4
Lift the top frame to full height and close the hinged spring cap over the spring. The locating pin in
the cap must be inside the top coil of the spring. Squeeze the locking tabs together, push the handle
fully down and release the locking tabs. (Figure 4)
NB: locking tabs must be fully engaged before releasing pressure from handle.

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Figure 5
The unit is now supported by the first spring (figure 5)
Repeat the process to insert the second spring (figure 6)
Figure 6
Warning: Both springs must be correctly located in the spring caps.
Replace the round plastic sheet (turntable models) evenly over the top frame and lower the angle
ring onto the centre pivot bearing. Ensure the angle ring rotates freely. (Figure 7)

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Figure 7
3.4 Installing the Palift Mobility Kit
Figure 8
A mobility kit enables manual relocation of a Palift.
The height of the Palift (compressed or elevated) increases by 25mm when installed.
Load capacity is unchanged.

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Warning: Palift must only be moved when empty.
The mobility kit has two components;
a. A dolly frame installed under the Palift
b. A wheeled Dolly with handle that raises the skid off its brake pads
The dolly frame fits under the fork tyne sockets of a Palift and accepts the wheeled dolly.
Installation of a mobility kit requires two persons and a forklift and must be done on smooth and level
ground.
To install the dolly frame, lift the Palift (with its springs installed) from the roller side using the method
shown in Figure 1 above.
Place the dolly frame underneath the Palift in the position shown (Figure 9).
Figure 9
Line up the adjustable feet lugs on the Palift with the locating pins on the dolly frame and lower the
Palift onto the dolly frame completely. Ensure that the fork channels of the Palift encapsulate the
roller enclosures completely and that the channels aren’t caught up on the bolts of the dolly frame.

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Figure 10
Figure 11
To move the Palift, install handle (Figure 10 and Figure 11), Pin on dolly must fully engage the socket
underneath the load bar.
Tilting the handle back will raise the front of the Palift, lifting it off its feet. In this mode, the Palift can
be moved around similar to a pallet truck.
To remove the handle, reverse the above process.
3.5 Location of the Palift
Palift should be positioned on a level surface. Optional adjustable feet are available for uneven or
sloping surfaces. The feet are threaded and can be screwed up or down to level the Palift. The
Mobile Base Palift is not suitable for loading or unloading on sloping ground.

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4.0 Operational Restrictions
4.1 Availability of a Forklift
A forklift is needed to remove a full pallet from the compressed Palift. Unloading a full pallet left the
forklift operator must lift the pallet all the way up until the Palift is completely extended, and the load
is clear of the Palift before the forklift reverses away, as illustrated below.
Warning: Do not attempt to mechanically lock the Palift in a compressed but unloaded state.
Release of the lock mechanism will result in the immediate release of the springs'
potential energy. This could cause serious injury or death to personnel in the vicinity and
damage the Palift.
4.2 Variation in Density of the Load
The Palift positions itself according to the weight and height of the load. Considerable variation in
the density of the load can be tolerated by one set of springs without a significant effect on the
performance of the Palift. If however, there is a large and frequent variation in the density of the
load, a hydraulic lift table may prove more suitable for the application. Contact your Palift agent to
discuss your requirements.
4.3 Layering of the Load
The Palift works most effectively when one layer of goods is completed (loaded or unloaded) before
the next layer is started. Rotating the load during the loading or loading process is best. If a single
item or only one layer of goods needs to be handled, a hydraulic lift table may prove to be more
suitable for the application.
4.4 Rotating the Turntable
Palift with Turntables are easily rotated by hand. Always rotate the load by pallet.
Caution: Do not attempt to rotate the load by grabbing beneath the turntable.

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4.5 Relocation of the Palift
PALIFT has built in sockets for relocation of EMPTY Palifts’ by a forklift. The unit can also be
relocated using the dolly relocation kit
Caution: Do not attempt to relocate a loaded Palift. This will damage the Palift and destabilise
the load.
4.6 Load Capacity
The load capacity of the Palift is, located on the side of one of the longitudinal members in the top
frame. The load capacity of 2000Kg is stamped on the identification plate. It is based on the load
being applied centrally and uniformly, as if the load were a full pallet.
5.0 Operating the Palift
5.1 Basic Operation
Palift automatically maintains the height of the top of the palletised load at the ideal height for manual
loading or unloading.
For unloading operations, a fully loaded pallet is placed on the Palift by forklift. As goods are
unloaded, the Palift begins to raise. To achieve the greatest benefit from the Palift, unload one
complete layer before starting on the next layer. With turntable models, the pallet can be manually
rotated to eliminate the need for the operator to reach over the pallet or walk to the other side of the
pallet.
The Palift works equally well for loading and unloading operations.
5.2 Spring Selection
Your Palift can be supplied with a combination of springs, selected from a standard range. There
are five standard springs available and each spring is identified by colour: Yellow, White, Red, Blue
and Green. Springs are selected based on the height and weight of the load to be palletised. The
Spring Selection Chart is shown below.

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5.3 Spring Selection Chart
Height of Loaded Pallet (mm)
(LOAD + PALLET)
Weight of Loaded Pallet (kg)
(LOAD + PALLET)
Spring
Combination
Number
Recommended Spring
Combination
1
White x 2
300Kg
2
Red x 1 + White x 1
400Kg
3
Red x 2
500Kg
4
Blue x 1 + Red x 1
600Kg
5
Blue x 2
700Kg
6
Green x 1 + Blue x 1
850Kg
7
Green x 2
1000Kg
8
Blue x 2 + Yellow x 2
1200Kg
9
Green x 2 + Yellow x 2
1500Kg
1800
1700
1600
1500
1400
1300
1200
1100
1000
900
800
200 300 400 500 600 700 800 900 1000 1100 1200 1300 1400 1500 1600 1700 1800 1900 2000
800
1700
1600
1500
1400
1300
1200
1100
1000
900
9
8
7
6
5
4
3
2
1
NOTE:
Yellow springs are smaller
Diameter springs that fit inside
standard diameter springs.
Yellow springs must never be
used alone.

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5.4 Changing the Springs
If the Palift is not ascending or descending at the correct rate, the springs may need to be changed
to a set that are better suited to the load.
Spring change procedures are set out in section 2.
Caution: OPEN AND CHANGE ONLY ONE SIDE AT A TIME, OTHERWISE THE PALIFT WILL
COLLAPSE.
Caution: The Palift top frame must be supported with a maintenance chock before both spring
caps are released or the top frame will plummet.
6.0 Other Features
Palift is available in multiple configurations:
a. Static base with turntable top. Incorporates built in fork sockets and turntable for easy
access to all sides of the load.
b. Static base with square top. Incorporates built in fork sockets and has a square non-
rotating top.
Either version can be relocated via forklift or with a proprietary mobility kit.
Palift is designed to take a standard CHEP/LOSCAM pallet or similar. Palift variations are available
to suit larger or heavier pallet loads if required.
The Palift incorporates a painted or hot dipped galvanised framework and electroplated hardware
and is suitable for wash-down applications. In acidic, highly saline or highly caustic environments,
the galvanising may be prone to premature failure. The Palift can be supplied with a special surface
treatment for these environments and a stainless steel model is also available for highly corrosive or
hygienic applications.
Adjustable feet are available as an option. Holes to accept the adjustable feet are incorporated into
the base frame of all Palifts. Adjustable feet should be used to level the Palift when used on sloping
or uneven ground.
Adjustable feet can also be used to elevate the base of the Palift by up to 100mm to allow underneath
access to a hand pallet truck. However, a Palift mobility kit is recommended for this application
instead as the increase in height is only 30mm when one is installed.
Note that the mobility kit cannot be used in conjunction with adjustable feet.

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7.0 Maintenance
Palift requires minimal maintenance.
Every six months (or more frequently for Palifts subject to heavy use or used in dirty environments):
a. Check roller paths for the ingress of debris and clean as necessary.
b. Check that all pivot pins and circlips are in place. Reinstate as necessary.
c. Check that the hinged spring cap locks are fully engaged.
d. Check that the turntable bearings are not seized or excessively worn. Replace as
necessary.
e. Check running faces of turntable bearings and rotating rings for caking of debris and
clean as necessary.
f. Inspect springs for damage to the protective finish and rusting of the steel beneath.
Exposed steel should be protected with metal primer (Kilrust or similar).
Your Palift springs are guaranteed for life provided the above is observed. On the rare
occasion that a spring breaks, the cause of the breakage can often be attributed to a
stress concentration caused by rust pitting.
g. Visually inspect all pivot points for signs of wear (pins in top, centre and base
weldments, rollers in top and base weldments.)
8.0 Warranty
Refer to Safetech complete Terms of Sale and Warranty at
http://www.safetech.com.au/terms-sale-warranty/

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9.0 Safetech Divisions
Head Office
Head Office – Moe, Victoria
Address: 39-45 Della Torre Road, Moe, Victoria, 3825
Postal Address: PO Box 360, Moe, Victoria, 3825
Phone: [phone]
Fax: [phone]
Email: [e-mail]
Service
Service Enquiries
Phone: [phone]
Fax: [phone]
Email: [e-mail]
Sales offices
Victoria
Address: 1/21 Lionel Road Mt Waverley VIC 3149
New South Wales
Address:14a/65 Elizabeth Street Wetherill Park NSW 2164
Queensland
Address: 12-23 Armada Street, Banyo, QLD, 4015
Western Australia
Address: 11/288 Amherst Road, Canning Vale, 6155

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10.0 Hazard Identification, Risk
Assessment & Control for Palift
10.1 Crushing and Shearing Injuries as a Consequence of Pinch
Points
The Palift has pinch points where the scissor legs meet and where the legs meet the platform and
the base. A crush injury is possible if a person’s body fouls these areas or is caught between the
Palift platform and the floor or other fixtures nearby.
10.1.1 Risk Assessment
The risk of such an injury is very slight. The Palift only moves in response to pallet loading or
unloading and the pinch points develop extremely slowly as the Palift moves. There is no serious
injury history associated with Palift in Australia. The passive nature of its operation means that any
injuries would be minor.
10.1.2 Control Measures
Palift’s scissor legs are spaced apart to ensure no pinch points between the scissors.
Train operators to ensure that no-one is likely to be caught in the moving parts before loading the
Palift. Clear the area around the Palift before operation.
10.2 Crushing and Shearing Injuries as a Consequence of Pinch
Points (Turntable)
The Palift has pinch points where the turntable rotates on its bearings. Each turntable has 10
bearings. A crush injury is possible if a person’s body fouls these areas or is caught between the
Palift turntable and the bearings.
10.2.1 Risk Assessment
The risk of such an injury is very slight. The Palift only moves in response to operator interaction
and the pinch points develop extremely slowly as the turntable rotates. The pinch points are not
easily accessible. There is no serious injury history associated with Palift in Australia. The passive
nature of its operation means that any injuries would be minor.
10.2.2 Control Measures
Palift’s turntable has a sturdy PVC cover to ensure no pinch points from the top of the unit.
Train operators to ensure that no-one is likely to be caught in the moving parts before loading the
Palift. Clear the area around the Palift before operation.
10.3 Crush Injuries due to Uncontrolled Descent
If both the springs are removed at once, the Palift could plummet.

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10.3.1 Risk Assessment
If the springs are changed one at a time, there is no risk of collapse. If a collapse did occur, medium
injuries could be suffered.
10.3.2 Control Measures
Ensure that all operators are familiar with the correct spring change procedure.
10.4 Crushing by Falling Palift or Load
Unstable loads may fall off the Palift on to the operator or other people.
10.4.1 Risk Assessment
If the load is placed centrally on the Palift and is compactly stacked, and if the Palift is located on a
solid and level floor, the risk is very low. Injuries that may occur could be serious.
10.4.2 Control Measures
Ensure that loads are stable and stacked securely on the Palift. Separate the Palift work area and
pedestrian areas. Ensure the area around the Palift is clear of persons before operation. Do not
exceed the load capacity of the Palift. Ensure that the Palift is positioned on a level floor or use the
optional adjustable feet to level the Palift. If the Palift incorporates a turntable top do not rotate the
load on the Palift rapidly.
10.5 Blow from Moving Palift
If the pallet is not unloaded properly from the Palift, it could spring up with some force and speed,
displacing the load or striking a person in close proximity.
10.5.1 Risk Assessment
There is a low risk of such a blow. Removal of the load necessitates the use of a forklift, which, in
itself, protects the load from the force of the springs. It also means that personnel are less likely to
be in very close proximity. If suffered, injuries could be serious.
10.5.2 Control Measures
Ensure that operators and forklift drivers are aware of the correct procedure for the removal of a load
from the Palift, and that personal are trained to keep clear of a forklift in operation.
10.6 Descent Due to Spring Breaking
In the event that a spring does break the Palift may descend displacing the load or striking a person
in close proximity.
10.6.1 Risk Assessment
There is a low risk of such an occurrence. The springs are designed to operate at relatively low
stress levels, and if maintained should not break. If a spring does break it will be under stress which
occurs when the Palift is loaded, therefore the descent would be over a short distance with little
chance of becoming caught under the load or displacing the load. If suffered, injuries could be
serious.