Palfinger ILSL 30, Owner'S Manual

Page 1: ...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 ...

Page 2: ...Button flush mounted control 13 5 3 Operation by Hand Held Remote Control 14 5 4 Operation by Foot Control 14 6 Preventive Maintenance and Quick Check 15 6 1 Maintenance and Care 15 6 2 Trailer to Tractor Connection Test 16 6 3 Lubrication 17 6 3 1 Lubrication Plan 17 6 3 2 Checking and Changing the Oil 19 6 3 3 Recommended Hydraulic Fluids 19 6 4 Decal Placement and Inspection 20 6 5 Quick Check ...

Page 3: ... 32 8 1 Ordering Spare Parts 32 8 2 Repairs 32 9 Warranty 33 10 Contact Address 34 Table of Figures Figure 1 ILSL Slide lift 8 Figure 2 Center Point of Load 11 Figure 3 Load Diagram ILSL 30 and 40 11 Figure 4 Hand Held Remote Control with Plug Socket Wiring 14 Figure 5 Lube Points18 Figure 6 Power Pack Side View 19 Figure 7 Power Pack Top View 19 Figure 8 Main Wiring 26 Figure 9 Hydraulic Schemati...

Page 4: ...t platform The Hydraulic Power Unit HPU is easily accessible for service and exchange The whole assembly slides out and can be serviced at that point To exchange the Hydraulic Power Unit HPU two hoses and the battery cables need to be disconnected The platform folded in half is supported by two torsion springs each on one side one support folding the other unfolding operation The platform in a sto...

Page 5: ...ughout the operation ONE MAN OPERATION Never let an outsider operate the liftgate while you are handling the cargo A misunderstanding can result in serious personal injury In the interest of safety it is important that all operating personnel properly understand the functions of the lift gate possible hazards dangers the load limits and load positioning for that specific unit IMPORTANT NOTICE Befo...

Page 6: ...which a load might fall 7 This is not a passenger lift Do not ride the lift with unstable loads or in such a manner that a failure would endanger you The lift is not equipped with a back up system to prevent falling cargo in the event of a failure The maximum loads must be observed and followed IMPROPER USE It is not permitted to use the tail lift As an elevating work platform To push loads To car...

Page 7: ...ld result in death or serious injury CAUTION indicates a potentially hazardous situation which if not avoided may result in 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 a...

Page 8: ...anual has been designed for use in conjunction with the ILSL series liftgate only which is designed for different capacities You have different options to determine the type of your Liftgate 1 Refer to the serial number tag on the Liftgate 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 8...

Page 9: ... 1 General View of Liftgate Figure 1 ILSL Slide lift Slider Rails Push Pull Cylinder Swing fixture Liftarm Lift cylinder Foot control Aux Battery kit Parallel arm Main section steel Tip section aluminum Cart stops Coil springs Folding assist ...

Page 10: ...nge for control system P 2007474 3 Clamp for cover P 2010169 4 Wire harness for control box J30 J32 P 2007410 6 Wire harness for power pack J1 P 2010018 7 Wire harness for circuit board power J1 J2 P 2007406 8 Wireharness with foot control switch J3 P 1330945 10 Cable for solenoid valve J1 J4 J42 1 P 67254198 4 1 3 2 8 ...

Page 11: ... 2 Slide Out 81 wire 3 no no no nc no no Toggle 4 Toggle 5 Toggle 6 Toggle Switch Optional Optional 3 3 Control Box No Description Part No 6 Control box with PC board and harness P 200 9304 Control box with cable without PC board P 200 7415 7 Complete outer plastic box P 200 9205 8 Operation label ATG ILUK 9 Flip down lid P 200 7476 10 Momentary turn knob P 200 7456 11 Contact block P 200 7457 22 ...

Page 12: ...o a maximum load The point of maximum load is rated at a defined distance The center point of maximum load is at 30 for all ILSL lift gates from start of Truck or Trailer Body as shown in Figure 2 Figure 2 Center Point of Load By increasing this distance the maximum load of the lift gate is decreasing An overview about the rating depending on the distance from the end of the platform is shown in t...

Page 13: ...clockwise down gate will lower out of its storage position 3 Slide out the liftgate Rotate the top button clockwise down to slide out the gate completelly untill it hits the slide stops at the end of the rail 4 Unfold the platform manually by using the straps 5 Fold the platform for storage Lower down the platform to about 3 off the ground To fold the platform flip the tip section onto the main se...

Page 14: ...the end of the rail 4 Unfold the platform Manually by using the strap 5 Operate the liftgate Use the top lift and bottom button lower to operate the liftgate to load and unload the truck trailer 6 Fold the platform for storage Lower down the platform to about 3 off the ground To fold the platform flip the tip section onto the main section 7 Sliding in Push the two top buttons to slide the lift gat...

Page 15: ...eatherproof boxes 1 2 Figure 4 Hand Held Remote Control with Plug Socket Wiring 5 4 Operation by Foot Control DOWN Step on switch 1 and hold wait between one and three seconds before you step on switch 2 UP Step on switch 2 and hold wait between one and three seconds before you step on switch 1 IF BOTH SWITCHES ARE NOT ACTIVATED WITHIN THREE SECONDS START OVER 1 2 Button No 1 UP Button no 2 DOWN ...

Page 16: ... it through preventive care Recommended bases for inspection and maintenance Depending on use Daily Monthly Quarterly cleaning x general lubrication of pins and bushings x general lubrication of Slider Rails with WD 40 and Push Pull Cylinder zerks with grease x oil level inspection x oil change x check hydraulic hoses and pipes for leaks x check controls and connections x check pins and pin retain...

Page 17: ...le on trailer b Run load test This will test entire circuit on trailer including circuit breakers ground between trailer batteries and trailer chassis Tractor and Trailer charging system test while connected 3 Ground battery load tester on tractor chassis d Hook up positive cable on positive pole of single pole plug recepticable on trailer b Run load test This will test entire circuit on tractor t...

Page 18: ...should be between the two marks 5 and 7 with platform in stored position Use a good quality of hydraulic fluid ISO 32 Change oil at least once a year preferably in the fall before the winter is getting closer The operation of the lift gate will accumulate condensation and some dirt which can interfere with the lift gate functions 6 3 1 Lubrication Plan All bearing points must be lubricated in acco...

Page 19: ...ocation of Grease Zerks 8 on each side 16 total Oil level in the power pack tank see marking inside of power pack reservoir Platform hinges Slide Rails and optional Cart Stops use WD 40 spray for lubrication Oil Change on Power Pack 4ea 3ea ...

Page 20: ...pty fill it up with hydraulic oil as shown on table 2 Figure 6 Power Pack Side View Figure 7 Power Pack Top View 6 3 3 Recommended Hydraulic Fluids TEMP RANGE BRAND 10 TO 150 F EXXON UNIVIS J26 MOBIL OIL DTE 13M CHEVRON AW MV32 ROSEMEAD MV 150 32 50 TO 150 F MOBIL DTE 13M SHELL AERO FLUID 4 EXTREME COLD TEMPERATURE USE MILITARY SPEC MIL H5606 Table 2 Recommended Hydraulic Fluids Hydraulic connecti...

Page 21: ...gent warning Elevating gate instructions B 1 ATG SWILFP Main Operation Control Box C 2 ATG XXXX Max Capacity please check the serial number plate to find out your specific capacity D 1 ATG CAB Liftgate Shut Off must be placed next to the Shut Off Switch E 1 ATG BKR Circuit Breaker Reset must be located at the circuit breaker F 2 ATG WLH Warning liftgate can crush G 2 ATG CTN Caution Always stand c...

Page 22: ...Revision 1 0 21 The picture below will help you to place all decals visible in order to get maximum operational safety Decal F Decal G Decal A Decal C Decal B Decal L ...

Page 23: ...he system by operating all functions several times 7 Check all electrical connections Clean and protect battery terminals and check for tightness 8 Inspect all the terminals on the solenoid operated valves at the port of the cylinder Lubricate the terminals for better protection from oxidation if needed Please check the valve block on the back of the main tube and its connections additionally 9 Gr...

Page 24: ...frame REINSTALL THE PLASTIC STRAP ON THE RUBBER COVER WHEN FINISHED Please check the following points before looking for faults Please change oil after working on hydraulic unit removal of valves opening of cylinder etc There is a possibility of injury if somebody other than an authorized technician works on the electrical system Injuries are possible if short circuits are caused by tools on the m...

Page 25: ...l also find an auxiliary battery kit as shown in the pictures below Truck Battery and Auxiliary Battery If circuit breaker reset arm is tripped push it back in as shown on the decal ATG BKR next to your breaker or on battery box lid 3 Are the vehicle batteries charged Check batteries and the truck trailer charging system Start truck and run engine in fast idle for charging the batteries If liftgat...

Page 26: ... to vehicle OK 6 Check the oil level in the power pack reservoir 7 Are there any damages on mechanical or electrical parts such as damaged cables 7 1 2 ON OFF switch on but all functions are dead Possible malfunctions 1 Short in hand held remote or its wire unplug Hand Control 2 Short in control box wire remove plug J 31 After disconnecting plugs reboot board by unplugging J 1 for 5 seconds and pl...

Page 27: ... Battery Shown for heavy applications Only Liftgate Mount Frame Main Truck Batteries 2 Ga Liftgate Power Cable Ground To Ignition Switch Ground Aux Batteries if applicable Battery Isolator if applicable Circuit Breaker Main Disconnect if applicable Circuit Breaker Figure 8 Main Wiring FOLLOW DOTTED LINE IF ISOLATOR OR AUXILLIARY BATTERIES INSTALLED ...

Page 28: ...l Schematics 7 2 2 1 Control board wiring and connector setup 2 GA CABLE CIRCUIT BOARD 3 Button Control or Hand Control UP SLIDE IN CENTER BUTTON DOWN SLIDE OUT ILSL KPLUS HACKBARTH 08 02 2010 Figure 1 Control board wiring schematic ...

Page 29: ...switch to ON OFF switch CYLINDERS LIFT 15 2 ea Figure 2 Plug setup on PC Board This graphic describes the different functions of each plug and where it is connected to Make sure every plug is in its correct position and fuses are in good conditions Connector description J 1 Main power input and connection to pump motor tray J 11 ON Off switch for truck setup J 2 Ground connection J 3 Platform equi...

Page 30: ...e valves They have to be activated for fluid to go through them in either direction To slide out S8 is activated to allow fluid to both sides of retractable cylinders To slide in S7 is activated to allow fluid to piston rod side of retractable cylinders Functions Lift M S1 S2 Lower S1 S2 S5 S11 Slide Out M S8 Slide In M S7 7 2 3 Hydraulic Schematic Figure 9 Hydraulic Schematic ...

Page 31: ...The gate is designed to lower down by gravity It will push the hydraulic oil out of the lift cylinder into the reservoir The oil passes the solenoid release valves S1 and S2 It also has to pass the energized S11 valve in the back of the mount frame and the shift valve S5 at the pump 7 3 3 Lift Up Function Motor starts running and double locking release valves S1 and S2 are energized The pressure i...

Page 32: ...Revision 1 0 31 AH AK BK AH AK BK BV AV S11 S8 S7 J42 80 J42 81 J1 12 7 4 ILSL Push Pull Valving Figure 32 Valve block setup at main frame ...

Page 33: ...wing information when making orders 1 Lliftgate model serial number 2 Designation and number of the spare part in accordance with the spare parts list 3 Designation and number marked on the individual component if available 8 2 Repairs Parts sent to PALFINGER Liftgates to repair must be accompanied by a letter in separate cover giving details and scope of the repairs required ...

Page 34: ...lled out in full The parts that are sent back to PALFINGER Liftgates marked with serial number and address become PALFINGER Liftgates property if the warranty claim is accepted All warranty claims must be received within 30 days of repair or replacement Including the following information 1 Liftgate model 2 Liftgate serial number 3 Description of problem 4 Itemized bill of repair with break down o...

Page 35: ...562 924 8318 E mail parts order customerservice PALFINGER com E mail technical support technicalservice PALFINGER com PALFINGER Liftgates LLC 572 Whitehead Road Trenton NJ 08619 Phone 609 587 4200 Fax 609 587 4201 E mail parts order customerservice PALFINGER com E mail technical support technicalservice PALFINGER com ...