MiniFix INSTALLATION MANUAL & CHECK-OFF SHEET ECN-M0262 Rev. 1.3, Date 07-15-2013 Part #90-0913-200 PALFINGER Liftgates, LLC. 15939 Piuma Ave., Cerritos, CA 90703 Tel (888)-774-5844 Fax (562)-924-8318 PALFINGER Liftgates, LLC. 572 Whitehead Road, Trenton, NJ 08619 Tel (609)-587-4200 Fax (609)-587-4201 Visit our website at www.palfinger.com for up to date information and notifications If you received this product with damaged or missing parts, Please contact PALFINGER Liftgates at (888)-774-5844
TABLE OF CONTENT 1. Important Notes:... 4 2. Mounting Notes:... 4 3. Chassis and Body Preparation for Installation... 5 3.1 Checks before assembly... 5 3.2 Preliminary work on the vehicle... 5 3.3 Preliminary work on the vehicle chassis (vehicles with C section frames)... 5 4. Mount Plate information... 6 4.1 Sprinter Model prior 2007... 6 4.2 Sprinter Model 2007 and newer... 7 5. Gate and Platform Installation... 8 5.2 Assembly of the Mount frame... 8 5.3 Assembly of the electrical installations... 8 5.3.1 Cab on/off switch - color and number coding... 9 5.3.2 Outside control button placement... 9 5.4 Attaching and finishing of the Platform... 10 5.5 Setting of Platform sensor B-16 and tilt cylinder... 11 5.6 Installing Flip Ramp... 12 5.7 Additional options and finishing work... 13 5.7.1 Foot control wiring and warning lights (optional)... 13 5.7.2 Setting of Lift arm sensor B-13... 13 5.7.3 Final Checks... 13 6. Hydraulic Diagram... 14 7. Electrical Diagram... 15 8. Minifix check off sheet... 16 9. Sprinter 2007 and up installation drawings:... 18 9.1 Sprinter 2500 / 128 Wheelbase... 18 9.2 Sprinter 2500 / 144 /170 /170 ext Cab Wheelbase... 19 9.3 Sprinter 3500 / 144 /170 ext. Cab Wheelbase... 20 9.4 Sprinter 3500 / 170 Wheelbase... 21 10. Quick installation reference guide... 22 11. Check Off Sheet... 26 Revision 1.3 2
Recommended Tools for Installation Metric Wrench Set Basic Screwdrivers Pliers Wire Crimp Pliers Test Light Snap Ring Pliers Hammer Metric Allen Set 1.5mm-10mm ½ Impact & Sockets Sm. Metric Socket Set Assorted Drill Bits Floor Jack or Equiv. Sm. To Med. Bottle Jack Forklift or O/H Crane Hand Held Grinder Paint Gun Pry Bar 3/8 Drill Motor 7/8 hole saw Heat Gun or Equiv. Nomenclature of Main Parts: B-16 Platform Sensor Revision 1.3 3
1. Important Notes: 1. Read Manual completely before beginning any work 2. For Sprinter Series MY2007 and newer models Mercedes-Benz requires auxiliary battery kits 3. Refer to your truck manufacturer s instructions before adding any auxiliary equipment. 4. Pay Special attention to items marked with this symbol: 5. All welding should be performed by qualified personnel per AWS standards 6. Always Ground closest to your welding point to prevent arcing through moving parts 7. Contact PALFINGER Liftgates. for Special Installations not covered in this Installation Manual 8. Do not paint cylinder shafts or nylon rollers (Use non-chlorinated brake cleaner to remove over spray) 9. Verify that pin lock bolts are tight 10. Grease all pivot points 11. Verify that ALL decals are placed properly (Contact PALFINGER Liftgates to replace any missing decals) 12. Final Check-Off-Sheet at rear of this manual MUST be filled out and kept in your records for future reference. 13. Refer to owner s manual for troubleshooting & repairs. 14. Mercedes allows the following lifting capacities for SPRINTER models at 24 center point of load 1) 1100 lb for SPRINTER Cargo Van Setup 2) 1320 lb for SPRINTER Chassis Cab Setup 2. Mounting Notes: 1. Read and clearly understand this manual BEFORE beginning ANY work Important!!! Min bed height: 18 with Van maximum loaded Max bed height: 31 with Van unloaded Minimum bed height dimensions are ALWAYS MAXIMUM LOADED TRUCK Call tech support before starting the installation if you have any questions or concerns on mounting dimensions Toll free: 888-774-5844 - technical support Revision 1.3 4
3. Chassis and Body Preparation for Installation 3.1 Checks before assembly 1. Does the liftgate match your order? 2. Do you have the correct mount plates for your particular chassis? - Each Sprinter chassis requires it own specific mount plates. 3. Are the assembly instructions for the PALFINGER Liftgates Minifix included? 4. Does the operating voltage of the PALFINGER Liftgates Minifix match the vehicle voltage? 5. Is a flip ramp included? 6. Observe the chassis guidelines of the vehicle manufacturer for accessory equipment. 7. Check size of battery for adequate capacity. 8. Is there a compartment under passenger seat designed for an auxiliary battery? Special tools required: 7/8 hole saw for installation of switches in side panel and basic metric wrenches. 3.2 Preliminary work on the vehicle 1. Remove any spare wheels and their mounts from the vehicle rear underside. 2. Remove any trailer and towing hitches as well as steps attached to the rear of the vehicle. 3. Replace special step bumpers fitted with standard bumpers. 4. Remove the licence plate on the rear doors and re-attach it in a visible position after assembly of the PALFINGER Liftgates Minifix (observe local and federal regulations). 3.3 Preliminary work on the vehicle chassis (vehicles with C section frames) 1. The PALFINGER Liftgates Minifix is supplied with vehicle-specific mount plates and fitted by means of the supplied assembly kit. 2. The 4 ea. drilled holes at the rear of chassis (i.e. mount for the trailer hitch) are used for bolting the mount plate to chassis. 3. Additional forward placed mounting points on the mount plates are to be drilled in the chassis frame. Revision 1.3 5
4. Mount Plate information VERY IMPORTANT: To install the Lift Gate it is very important to have the right mount plates. They are dependent on the Wheelbase (WB) and Chassis type: - Chassis 2500: Single Rear Wheel - Chassis 3500: Dual Rear Wheel 4.1 Sprinter Model prior 2007 single wheel 118"/140"WB single wheel 158"WB 18-1/4" 26-1/2" Left: P-2005081 Right: P-2005083 Left: P-2004489 Right: P-2004492 dual wheel 140"WB 29-1/2" dual wheel 158"WB 23" Left: P-2008031 Right: P-2008033 Left: P-2004501 Right: P-2004504 MINIFIX Installations Kit # QTY Description 1 18 Lock Washer 1/2" (12mm) 2 18 Nuts 1/2" (12 mm) 3 36 Washer 1/2" (12mm) 4 12 Bolts 1/2" x 4" (12mm x 100mm) 5 6 Bolts 1/2" x 1,5" (12mm x 40mm) Revision 1.3 6
4.2 Sprinter Model 2007 and newer The Chassis and the dimensions have changed beginning with the Model year 2007. Images below and matrix are showing the available models and the according mount plates Chassis WB Mount Plates (left / right) Spacer Mounting Kit 2500 128 2012508 / 2012510-2004579 2500 144 /170 /170 ext Cab 2012512-2004579 3500 144 /170 ext. Cab 2012512 Only 144 / 4ea. P-2012762 2004579 3500 170 2012764 / 2012766 2ea. P-2012760 2012768 Mount plates: 2500-128 WB 3500 170 WB 17-1/4" 18-1/4" P-2012508 le P-2012510 ri 2500/3500 144 / 170 / 170 ext. Cab WB 24" P-2012763 P-2012764 le le P-2012766 ri ri P-2012512 le/ri Mounting Kit 2004579 Mounting Kit 2012768 Quantity Parts Quantity Parts 24 Washer 24 Washer 12 Nuts M12 12 Nuts M12 12 Bolts M12x100 8 Bolts M12x120 4 Bolts M12x100 7
5. Gate and Platform Installation Installation drawings for each mounting situation are attached at the end of this manual (see 10. Sprinter 2007 and up installation drawings - Page20-23) 5.2 Assembly of the Mount frame 1. Vehicle-specific mounting plates are fitted by means of the supplied assembly kit. 2. The power pack unit is normally mounted on the forward surface of the mount frame. If there is insufficient depth for installation, mount the unit elsewhere on chassis. 3. Install the mount plates first with the 4 bolts at the rear - leave the plates somewhat loose so there is room to install the mount frame in between them. 4. Bring the mount frame into position underneath the vehicle using a floor jack and bolt into position with the supplied 6 ea M 14 bolts (grade 8-9/16 bolts) 5. After the mount frame is in place, drill the two forward holes in the frame and install these bolts. Do not tightening all the bolts until the gate is operational and platform is in place. 6. Finish the tightening of the 12 ea. Mount plates to frame bolts after unit is operational and in place to determine that the platform is storing square to body and meets floor height. 5.3 Assembly of the electrical installations 1. Use the attached PALFINGER Liftgates Minifix electric schematic (see page 14) and observe the set-up guidelines of the vehicle OEM. 2. Run the battery cables to the battery. Make sure not to route any wires in a way where it get damaged or damages the vehicle harnesses. Shorten cables if required and affix cable lugs! Do not attach power cable to gas tank or gas filler hose! 3. Attach circuit breaker (see picture 1) to the cable lug, connect with copper brass bar to the positive pole of the battery. 4. Route the control unit harness to the cab. Choose a location on the instrument panel in the cab and install cab on/off switch within view of the driver. 5. If the vehicle already has a factory install cab on/off switch, connect PALFINGER Liftgates Minifix in accordance with PALFINGER Liftgates supplementary circuit diagram; if necessary, request circuit diagram from PALFINGER Liftgates. 6. Make sure there is sufficient ground connection between lift gate power pack and batteries. 7. WARNING! On hazardous goods vehicles, connect the ground cable to the battery or in accordance with the set-up guidelines of the respective vehicle manufacturer. RESET picture 1: resettable circuit breaker 150 Amp 8
5.3.1 Cab on/off switch - color and number coding "Off" Symbol Blue (BS3) Green/Yellow (-) White (#1) Blue (#4) Red (#2) Cable wires are marked: #1 = Status lights for L.E.D. Lights - WHITE #(-) = Ground to L.E.D. Lights - GREEN/YELLOW #2 = 12 Volt Lead from Batteries - RED #4 = Control Power to Lift gate - BLUE 5.3.2 Outside control button placement Mount operating buttons on right side rear of body (see diagram below). Center switches approximately 15 from rear of corner post. ø 7/8" 9" 3" OEF Z.T SE Function of push buttons: OEF = tilt open platform SE = lowering platform SE+ZT = lift up platform OEF+ZT = tilt close platform 8. Installation of hand remote must be set up in a way where it can t be damaged during normal operation. The operating buttons must be arranged in accordance with the diagram above. The operating decal gives circuit logic details. The operating decal is furnished with a self-adhesive reverse side and is applied directly to the panel of the vehicle outer wall. 9
5.4 Attaching and finishing of the Platform When attaching the platform be careful that it does not drop since there is no fluid in the cylinders at this point. Use suitable lifting equipment to raise the lift arm until it reaches the cargo floor height. Support the arm with a jack. Make sure the arm moved freely while lifting it up. 1. Set and lock the lift arm stops of the lifting mechanism on the main tube. Important: Set both lift arm stops to the same height, otherwise the lifting mechanism or body can be damaged (see diagrams below). Lift Arm Stops Place lifting gear at cargo floor height Set and lock lift arm stops in upper position 2. Assemble platform and lifting gear using supplied T-shape tool to set connecting pins in position. Secure all pins with the 8 mm locking bolts and secure with lock tight. 3. To attach the tilt cylinder to the platform, attach it to the lift arm assembly first. IMPORTANT! Cylinder Piston end has to be attached to lift frame, core part facing platform. 4. Use the operating buttons for opening and closing to move the tilting cylinder to a length that allow the cylinder to be bolted on to the platform. To do this, hold the angle sensor b16 with the cable down (this allows the cylinder to power retract when using opening button). T-shape tool 2. Attach tilt cylinder and platform where platform and cylinder holes match Lines for alignment Attach platform to cylinder in an angle 45 to 90 degree 1. Attach Platform in horizontal position Platform attachment to lifting gear Attachment of tilt cylinder 10
5.5 Setting of Platform sensor B-16 and tilt cylinder MINIFIX INSTALLATION MANUAL 1. Mount the platform sensor b16 to the platform clip, as shown in picture 1, so that the filling faces towards the driver side. 2. Move the lifting gear all the way up to the truck bed against the lift arm stops to insure horizontal platform is flush with the truck bed. If necessary, readjust lift arm stops. B-16 sensor filling towards driver side Picture 1: B-16 setup Adjust tilt cylinder clevis and lock in place with lock nut when platform is in final position Picture 2: adjusting tilt cylinder 3. Remove the emblem on the back door and replace with supplied triangle rubber bumper, like shown in picture 3. Close the platform to the body as far as possible, make sure the platform does not hit the body. (Tilting cylinder is extended to the limit stop = (max stroke!!)) Relieve the pressure in the tilt cylinder by hitting the open button. By turning the piston rod, using an open-end wrench, you are able to adjust the length of the piston to store platform into the designated position. If required, repeat the setting procedure. With platform in position, tighten the lock nut of the piston.(see picture 2) Truckbody Picture 3: installation of rubber bumper Rubber bumper For the final position of the platform the tilting cylinder must be extended to the full stroke in the closing position. Make sure, lift arm is all the way up against the lift arm stops. The platform must not hit the body in any circumstances as this can otherwise damage the body. 11
5.6 Installing Flip Ramp Mount the flip ramp supplied inside the vehicle. Stow the ramp in the vehicle directly behind the closed door. The ramp has to be installed to the vehicle floor with the two supplied hinges. There has to be a gab of 2.0 between the end of the flip ramp, sitting on the platform and the side profiles with gate at bed height. To measure this distance the platform has to be in a horizontal position. 2.0" Vehicle Flip Ramp Platform Side Profile 12
5.7 Additional options and finishing work 5.7.1 Foot control wiring and warning lights (optional) 1. Close the platform up towards the body. 2. Loosen cable retainer (black plastic cap on the head section of the platform), pull the cable with the plug for the foot-operated switch and warning light out of the platform (make sure there is enough cable length!) and refit the cable retainer. Run the cable along with the release valve cable at the hydraulic hose and connect the plug on the board. Secure the harness so it does not get damaged during operation 5.7.2 Setting of Lift arm sensor B-13 1. All fitted cables must be routed carefully and secured. 2. Lower the platform to about 8-10 above the ground and set the lift arm switch b13 on the lift arm in a horizontal position. 3. Loosen the M6 adjustment bolt, retighten after setting and bend the metal clip to fix position of the switch. Position for adjusting B-13 Switch bend clip to secure B 13 switch after tightening B 13 switch position bend clip to secure B 13 switch after tightening 8" to 10" 5.7.3 Final Checks 1. Raise, lower, open and close the platform several times to de-aerate the cylinders. 2. Use the brackets on the platform underside as holders for the hydraulic hoses and electrical cable that extend out of the platform. 3. Check the oil level with the platform lowered. Check that all electrical, hydraulic and mechanical connections are tight and that no wires are rubbing during the gate operation. 13
6. Hydraulic Diagram Functions: S1 = Release Valve for lowering function S2 = Release Valve for tilt down function R1 = Flow Restrictor located inside hose adaptor on lift cylinder R2 = Flow Restrictor located inside hose adaptor on tilt cylinder S5 = Shift Valve is activated on tilt up and lowering function R5 = Restrictor Valve located in power pack Flow Divider is activated, when fluid is going back into the power pack If Flow Divider is loose or hanging up the fluid is circulated back in to tank 2 2 Shift Valve S5 Restrictor Valve R5 Flow Divider Functions: Lift: M Lower: S1+ S5 Tilt Up: M+S5 Tilt Down: S2 Horiz. Open: M+S2 Pressure Relief 2850 PSI 200 bar Datum 01.08.08 HACKBARTH Hydraulic Schematic Minifix 14
7. Electrical Diagram Legend : gn : green bl : blue br : brown wt : white ye : yellow bk : black gy : green-yellow 150 CIRCUIT BOARD # 2 BLACK # 4 BLACK (+) # 1 BLACK GREEN / YELLOW (-) 4 WIRE CABLE 2 GA CABLE MINIFIX K1PLUS LI : Lift Up LO : Lower Down OP : Open Gate CL : Close Gate OPTIONAL WIRELESS HANDCONTROL OPTIONAL WARNING LIGHTS & FOOT CONTROL 15
8. Minifix check off sheet MINIFIX Check Off Sheet JOB NO. GATE NO. VIN NO. OWNER'S MANUAL IN CAB ON-OFF SWITCH WORKING & DECAL IN PLACE WIRING 1. Power Cord Secured OPERATION 1. All Functions 2. Cables Not Rubbing Steel Up/Down, tilt up down 3. 12V Control Wire Secured Hand remote/ foot controls 4. Loomed & Stapled 2. Up Stops In Place 5. Circuit Breaker & Fuse 3. Platform Meets Body Installed & Decal In Place HYD. LINES SECURED 1. No Rubbing On Frame 2. No Rubbing On Platform 3. Up-Down Clear 4. Storing Platform Clear 4. 24mm Platform Bolts Tight HYD. OIL 1. None At Hoses LEAKS 2. None Power Pack FINAL 1. Piston rod clean from paint 3. Cylinder INSPECTION 2. Lights Working On Chassis 3. Lic. Plate Bolts & Lights 4. Decals Installed 5. Rubber & Plastic Caps In Place 6. Gate Painted Completely 7. Body Clean Around Gate 8. Pins Greased - PUMP 1. Check Fluid With Platform On Ground 16
& MOTOR 2. Connections Tight With Heat Shrink 3. Power Cable Tight OPTIONS 1. All Options On Gate 4. Ground Cable Tight 2. Circuit Breaker Working 5. Breather Installed & Decal In Place 6. Cables Tied Off 3. Cart Stops Working 7. Fuses Tight CHECKED BY PINS 1. Grease Zerks In Place 2. Red Grease Caps On Zerks DATE 3. Bolts Tight On Pins Note: PALFINGER Liftgates recommends that this form is filled out and kept for your records. 17
9. Sprinter 2007 and up installation drawings: 9.1 Sprinter 2500 / 128 Wheelbase MINIFIX INSTALLATION MANUAL 18
9.2 Sprinter 2500 / 144 /170 /170 ext Cab Wheelbase MINIFIX INSTALLATION MANUAL 19
9.3 Sprinter 3500 / 144 /170 ext. Cab Wheelbase 20
9.4 Sprinter 3500 / 170 Wheelbase 21
MINIFIX INSTALLATION MANUAL 10. Quick installation reference guide 22
MINIFIX INSTALLATION MANUAL 23
MINIFIX INSTALLATION MANUAL 24
MINIFIX INSTALLATION MANUAL 25
11. Check Off Sheet MINIFIX INSTALLATION MANUAL JOB NO. GATE NO. OWNER'S MANUAL IN CAB ON-OFF SWITCH WORKING & DECAL IN PLACE VIN NO. WIRING 1. Power Cord Secured OPERATION 1. All Functions Operate On 2. Cables Not Rubbing Steel outside Control & Hand Control 3. 12V Control Wire Secured 2. Up Stops In Place 4. Loomed & Stapled 3. Platform Meets Body 5. Circuit Breaker & Fuse 4. Sensor Set For Proper Installed & Decal In Place Function 6. Loop in platform sensor wire 5. Warning lights stop flashing when gate turned off HYD. LINES 1. No Rubbing On Frame 6. Cab switch not flashing when SECURED 2. No Rubbing On Platform platform stored and switch off 3. Up-Down Clear 7. Platform hits rear sill even HYD. OIL LEAKS 4. Storing Platform Clear at the same time 9. No Paint on cylinder shafts 1. None At Hoses 2. None Power Pack 3. Cylinders FINAL 1. Platform Touches Ground WELDS 1. Full Welds Mount Brakets INSPECTION 2. Lights Working On Chassis 2. Ground Off / Clean 3. Lic. Plate Bolts & Lights 3. Frame Capped Off 4. Decals Installed 5. Rubber & Plastic Caps on 6. Gate Painted Completely 7. Body Clean Around Gate PUMP 1. Check Fluid With Platform On Ground 8. Pins Greased & MOTOR 2. Connections Tight With Heat Shrink 9. Cylinders Clean 3. Power Cable Tight 10. Clamp on cover 4. Ground Cable Tight 11. Exhaust mud flaps are ok 5. Breather Installed 6. Cables Tied Off OPTIONS 1. All Options On Gate 7. Fuses Tight 2. Circuit Breaker Tight 8. Clamp on cover 3. Cart Stops Working PINS 1. Grease Zerks In Place CHECKED BY 2. Red Grease Caps On Zerks 3. Bolts Tight On Pins 4. Ground Rollers On DATE Note: This must be filled out and kept for your records. A copy of this sheet must be presented to PALFINGER Liftgates for any warranty compensation 26