Palfinger ILU 40, Installation Manual & Check-Off Sheet

Page 1: ...ritos 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 ...

Page 2: ...ift arm Up stop installation and rail stops setup 18 5 6 Control box installation 19 6 Gate adjusting and detailing 20 6 1 Setting B 13 lift arm sensor 20 6 2 Setting B 15 Platform sensor 21 6 3 Platform adjusting with bolts 22 7 Electrical Installation 23 7 1 Breaker Installation 23 7 2 Wiring schematic main battery power Truck setup 24 7 3 Wiring schematic main battery power Trailer setup 25 7 4...

Page 3: ...iring 17 Figure 13 Installation of up stops 18 Figure 14 Mount plate slide stops 18 Figure 15 Control box placement 19 Figure 16 B 13 lift arm adjustment 20 Figure 17 B 15 adjustment on platform 21 Figure 18 Platform wiring with B 15 and controls 21 Figure 19 Circuit breaker installation 23 Figure 20 Main wiring truck setup 24 Figure 21 Main wiring trailer setup dual pole charging system 25 Figure...

Page 4: ...Crimp Pliers Test Light Snap Ring Pliers Hammer Metric Allen Set 1 5mm 10mm 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 Grease Gun Heat Gun or Equiv Min 250 Amp Welder Cutting Torch or Equiv ...

Page 5: ...avoided could 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 t...

Page 6: ... 8 Verify that pin lock bolts are tight 9 Grease all pivot points 10 Verify that ALL decals are placed properly Contact PALFINGER Liftgates to replace any missing decals 11 Final Check Off Sheet at rear of this manual MUST be filled out and kept in your records for future reference 12 Refer to owner s manual for troubleshooting repairs Important Dimensions Refer to line drawing on following pages ...

Page 7: ...and MINIMIZE THE F DIMENSION Minimum bed height dimensions are ALWAYS MAXIMUM LOADED TRUCK Floor Height Ranges Max Unloaded Truck Min Loaded Installing a gate at or close to minimum bed height normally results in a gate that will NOT open and close from stored position if the minimum floor height is exceeded when truck is loaded Call tech support before starting the installation if you have any qu...

Page 8: ...l width of suspension angles Liftgate Type Type of Body Van Flatbed Refer Make GVWR Chassis Dimension Sheet Phone Fax E mail Type of rear door Roll up Swing Flip up Trailer Trailer H Verify flush treshold or other set up A E F D B C G Figure 1 Trailer dimension sheet me A Bedheight B Top of floor to bottom of frame C Rear sill height D Spring hanger to end of body E Tire to end of body F Gas tank ...

Page 9: ... IMPORTANT Before starting the installation make sure that you have your own reference sheet that was supplied to PALFINGER Liftgates together with the installation lay out drawing Compare it with the truck you are about to start the installation on If the units are different than the supplied lay out contact your supervisor and PALFINGER Liftgates to go over the differences Do not start installat...

Page 10: ...4 Installation Dimensions Revision 1 5 10 4 1 General Bed Height Ranges for ILU liftgates Minimum bed height is when truck trailer is loaded to MAX GVW all dimensions in inches ILU 40 50 800mm arm 36 56 ...

Page 11: ...ith installing the liftgate slide rails to the frame IMPORTANT Truck Installation Before start of installation make sure body long rails are connected to truck frame welded with flat bars and secured against forward movement of the body o If body and frame are not connected lift gate might push body forward Bed height top of bed to floor when air bags are inflated and on flat ground dim Y Mount fr...

Page 12: ...cut out needed If no cut out height is determined in drawing cut out for best fit Keep at least a minimum of 4 of sill Reinforce every cut out of the sill to regain sill strength required by truck trailer OEM 46 12 12 70 Reinforce cut outs Figure 5 Sill cut out dimensions rear view Figure 6 Sill cut out sideview To avoid interference with the body you need to cut out the back sill Height of the cu...

Page 13: ... done when gate and platform are installed and you raise up gate for the first time That gives the opportunity to keep as much of the eyebrow as possible to keep rear frame strength IMPORTANT A proper preparation of the truck trailer sets the basics for a safe clear and fast installation process and assures a proper function of the lift gate without damage to truck trailer or lift gate ...

Page 14: ... with the liftgate matches the truck and gate you are about to install 2 Install the slider rail frame according to drawing sent with the gate Weld brackets with 2 x 2 of welds on each side for adjustment purposes 3 When gate is completely installed and tested for proper function weld a 100 around the brackets to assure a save and secure connection of gate and truck frame ADD STEEL BACKER PLATE IF...

Page 15: ...hment 3 Connect platform to frame by using supplied pins and lock bolts 4 Connect lift arm to inside clevis holes Tighten lock nuts at pin tab to avoid pin getting loose 5 Connect tilt cylinder to outside holes at clevis Tighten lock nuts at pin tab to avoid pin getting loose a To extend or retract tilt cylinders you have to connect the power supply of the gate see chapter 5 4 and chapter 5 3 b Ho...

Page 16: ...itive 2 4 and the negative 1 gr ye post of the batteries Control Power 4 Wire Cable Truck Application Always wire to truck battery Trailer Application wire to trailer battery 20 Amp In Line Fuse Wires marked 2 4 Black go to hot 1 and green yellow go to ground PC board 2 27 15 Amp fuses J1 Plug 2 4 E E gr ye 1 J2 Plug Figure 10 Board control power wiring connection Ground Cable Ground at trailer fr...

Page 17: ...nstall B 15 sensor to platform and connect foot control and warning light cables 6 Push all excessive cable inside platform to protect connections from environmental influences TIRE Cable Cover Clamp B 15 Sensor Liftarm Platform Profile Wire Ties Warning Light Foot Control option Harness Loop per drawing to allow for proper movement Figure 12 Platform installation and wiring 5 4 1 1 Swing door pla...

Page 18: ...ycles and check perfect match of gate and body floor Make sure slide stops are tight and alignment of platform and body is ok Make sure platform is aligned and flush with floor Up Stops MUST be installed to avoid damage to platform or sill Install stops when 3 16 Angle is still between platform and body make sure Up stops are sitting tight against lift arm when platform in upper position 3 16 Use ...

Page 19: ...Control box installation Install the control box on the passenger side mounted arm Run the cable along the slide rail and tie it down so it cannot interfere with the mount plates when gate is sliding in or out Figure 15 Control box placement ...

Page 20: ...orm tip will tilt towards ground if operator stays on the lower switch for about 3 seconds after nylon rollers touching ground Cycle platform several times to check operation after tightening Fold down Lock Tab tightly onto Lift Arm see Figure 16 At NO time the platform tip should tilt towards ground while lowering Platform should only tilt after Nylon rollers contact ground and operator is on the...

Page 21: ...inch points Verify B 15 is set correct when cable restrainer is parallel with platform surface B 15 is working correct if platform finds preset level position while tilting up form ground position If platform is only lifting without leveling out battery power supply is low check and charge battery On trucks start truck and run in high idle for 5 10 Min Cable Cover Clamp B 15 Sensor Liftarm Platfor...

Page 22: ...al to the platform To level the platform the bolts need to be adjusted To tilt the tip section up the bolts have to be rotated counter clockwise To tilt the tip down the bolts have to be rotated clockwise To adjust the bolts the platform needs to be folded 1 Adjust bolts to the right length for a level platform 2 Tighten down the lock nuts properly for a save fit 2 Screws on each side of the platf...

Page 23: ...in serious damage to the equipment Never jump the 150 Amp circuit breaker at the batteries unless otherwise instructed by the PALFINGER Liftgates technical support center Assure all connections are tight and securely fastened Heat shrink any connection to all cables Never secure a cable in a way where it can make contact with other wiring brake fuel or air lines etc or get pinched against other ob...

Page 24: ... Ground Cable Ground Third 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 Circuit Breaker Figure 20 Main wiring truck setup ...

Page 25: ...iftgate Mount Frame 2 Ga Liftgate Power Cable Ground Aux Batteries Figure 21 Main wiring trailer setup dual pole charging system Ground Cable Ground Third Battery Shown for heavy applications Only Liftgate Mount Frame 2 Ga Liftgate Power Cable Ground Aux Batteries Ground Figure 22 Main wiring trailer setup single pole charging system Dual pole plug Single pole plug ...

Page 26: ...ll the 2 Ga positive and negative battery cables securely from mount frame to battery and truck trailer chassis with proper service loop for sliding liftgate Make sure the cables can not catch on anything during the slide test several times Running the cables along the frame secure the cables every 12 inches Trail Charger 7 way plug aux pin for tractor ignition switch 7 way plug white for tractor ...

Page 27: ...ack Blue optional White Figure 24 Cab Cut off switch connection 7 5 2 Trailer setup Trailer units do not have a cab switch The on off switch is integrated into the control box The switch is on the right hand side in the control box It is prewired and does not need any additional work Main power is been taken of J 11 2 and returns to the board through J 30 4 All 4 terminals are internally hardwired...

Page 28: ...T BOARD WIRELESS HANDCONTROL OPTIONAL Legend gn green bl blue br brown wt white ye yellow sw bk black gy green yellow LI Lift Up LO Lower Down OP Open Gate CL Close Gate WARNING LIGHTS Platform Sensor B 15 Lift arm Sensor B 13 Figure 26 Control board wiring schematic Verify that this jumper is set otherwise there will be no flashing light on the platform ...

Page 29: ...2ea PUSH PULL CYLINDERS Figure 27 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 2 Ground connection J 3 Platform equipment Warning lights and foot controls J 32 Control butto...

Page 30: ...on both sides of the wire harness 10 wire harness ILU Plus control box setup Figure 28 Control box wiring schematic J 2 2 Main Battery power J 30 Control box PC board input gate operation functions J 32 Control box PC board input gate sliding functions 80 slide in 81 slide out 7 9 2 Button Remote Hand Control The hand held remote control plug is integrated into the control box No separate wiring i...

Page 31: ...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 Tilt Up M S5 Tilt Down S3 S4 Slide Out M S8 Slide In M S7 Figure 29 Hydraulic schematic ILU ...

Page 32: ... Slide Rails and optional Cart Stops use WD 40 spray for lubrication Open platform and raise lift gate to bed level Remove red caps apply grease until grease begins to flow from bushing ends Lower platform to ground and repeat Cycle platform open and closed several times and grease again Wipe excess grease from joints and replace ALL red caps Figure 30 Grease and Lubrication points 3x 3x 3x 3x ...

Page 33: ...ntrol Box C 1 ATG FT Notice for Foot Control if applicable D 2 ATG XXXX Max Capacity please check the serial number plate to find out your specific capacity E 1 ATG CAB Liftgate Shut Off must be placed next to the Shut Off Switch F 2 ATG WLH Warning liftgate can crush G 2 ATG CTN Caution Always stand clear of platform area H 1 ATG BKR Circuit Breaker Reset must be located at the circuit breaker J ...

Page 34: ...Revision 1 5 34 The picture below will help you to place all decals visible in order to get maximum operational safety Decal A Decal C Decal D Decal B Decal F Decal G Decal J Decal K Decal L ...

Page 35: ...lts Removed on On Auto Tilt Knuckle LEAKS 2 None At Power Pack Auto Tilt Knuckles 3 Cylinders FINAL 1 Platform Touches Ground WELDS 1 Full Welds Mount Plates INSPECTION 2 Lights Working On Chassis 2 Ground Off Clean 3 Lic Plate Bolts Light 4 Dock Bumper Welded 4 Decals Installed 5 Frame Capped Off 5 Rubber Plastic Caps In Place 6 Gate Painted Completely PUMP 1 Check Fluid With Platform On Ground 7...