Palfinger LIFTGATES ILM plus Series, Troubleshooting Manual

Page 1: ...15 15 Hydraulic Schematic Power Close 16 16 Hydraulic Schematic PC Lift Function 17 17 Hydraulic Schematic PC Open Function 18 18 Hydraulic Schematic PC Lower Function 19 19 Hydraulic Schematic PC Close Function 20 20 Platform not lowing down Test 21 21 Check ground on solenoid valves 22 22 Testing solenoid valves and cables 23 23 Pump pressure adjustment 24 24 Gate chattering or sticking in rails...

Page 2: ... Chain Power Open Close Cylinder if applicable Operating Controls Rail Platform Storage Latch Load Center of Gracity Hydraulic Power Unit Inside Serial tag 13 5 1 6 6 15 1 15 4 15 2 15 3 15 3 15 2 15 5 15 4 15 1 15 6 15 2 1 2 2 2 3 2 2 3 2 3 16 3 16 2 16 5 16 4 16 1 16 6 16 15 2 15 7 Open Close Restrictor location ...

Page 3: ...ting Temperature 45 C to 23 C 49 F to 73 F Pour Point 57 C 71 F Flash Point 128 C 262 F Density 15 C 59 F kg L 0 834 Viscosity cSt 40 C SUV 100 F cSt 100 C SUV 210 F cP 50 C 58 F 13 0 69 7 4 95 42 5 1 310 Alternative Fluids Temperature Range Fluid Brand 30 TO 150 F EXXON UNIVIS J26 MOBIL DTE 13M CHEVRON AW MV32 ROSEMEAD MV 150 32 50 TO 150 MOBILE DTE 11 SHELL AERO FLUID 4 41 SHELL TELLUS 15 Extrem...

Page 4: ...2 Button Control or Toggle Switch Seal with Heat Shrink Seal with Heat Shrink Raise Green Lower Black Power Red Lower Solenoid Black Ground Lower So Manual Open and Close will have two button controller 9 901 ftgate Control Lowe Raise Green 5 Lower Black 6 Power White 4 70 0709 903 Optional Inside Coil Cord Remote 2 Button Control Diode Diode Inside Remote Schematic Motor Solenoid S1 Lift Lower Va...

Page 5: ...5 ILM plus Series Chain Routing Standard ILM ...

Page 6: ...6 ILM plus Series Chain Routing Above Floor ILM ...

Page 7: ...e of platform for damage or seized Check open close cylinder for damage or leaks a Initial Checks Check Cab Switch is ON Optional Check that Circuit Breaker at battery box has not been tripped Check that 15 amp fuse at Motor Solenoid is ok Check for shorts ground faults or open circuits e g power lines connected to the ground or a broken cable or connection Check batteries Batteries should be full...

Page 8: ...oir and place line inside hole for vent and press down button on controller first making sure all obstacle s are clear and operator is safely clear If gate lowers with this test then problem is in pump assembly remove and replace pump and motor assembly for this test see illustration on page 13 Check if Lift Lower valve on cylinder is energized If not check power supply to up down switch and signa...

Page 9: ...ns but platform does not raise Check lift cylinder for damage or chain for broken chain links See drawings page 15 16 a Initial Checks Check Cab Switch is ON Optional Check that Circuit Breaker at battery box has not been tripped Check that 15 amp fuse at Motor Solenoid is ok Check for shorts ground faults or open circuits e g power lines connected to the ground or a broken cable or connection Che...

Page 10: ...for 10 seconds Deadhead b Motor is not running Check power supply to open close and up down switch and for voltage at motor solenoid and open close valve while activating up function Check motor solenoid If it is getting power but you do not hear click you should change the motor solenoid You hear it click check if the motor gets power If yes check the motor of correct function d Motor is running ...

Page 11: ...oid Black Lower Solenoid Black Power Red Lower Black Raise Green Seal with Heat Shrink Seal with Heat Shrink 70 0709 903 Optional Inside Coil Cord Remote 2 Button Control Power White 4 Lower Black 6 Raise Green 5 Power 4 Blue Lower 6 Yellow Green Raise 5 Brown 70 0709 906 Remote Harness for Optional 2 Button Control or Toggle Switch Power Red Starter Green Lower Black 70 0709 902 Main Liftgate 2 B...

Page 12: ...tic Manual Closing Lift Cylinder Cylinder Valve Body Pump Unit Relief Valve 2900 psi Filter Pump Flow Control Press Comp 1 0 gpm Port Port Cap Port Locking Valve Main Cylinder Shuttle Valve Reservoir Tank Hydraulic Schematic Manual Closing S1 Lift Lower Valve Motor Motor ...

Page 13: ...Body Pump Unit Relief Valve 2900 psi Filter Pump Flow Control Press Comp 1 0 gpm Port Port Cap Port Locking Valve Main Cylinder Shuttle Valve Reservoir Tank Hydraulic Schematic Manual Closing M Lift Function Green 12 Volt Power Active Red High Pressure Blue Low Pressure Lift Function Motor S1 Valve S1 Lift Lower Valve ...

Page 14: ...ody Pump Unit Relief Valve 2900 psi Filter Pump Flow Control Press Comp 1 0 gpm Port Port Cap Port Locking Valve Main Cylinder Shuttle Valve Reservoir Tank Hydraulic Schematic Manual Closing Lower Function Green 12 Volt Power Active Red High Pressure Blue Low Pressure Lowering Function S1 Valve S1 Motor Lift Lower Valve ...

Page 15: ...ry Cable 150 amp Circuit Breaker 12V Power Supply Important Note All connectors are to be insulated and weather sealed In Line ATC Fuse 15 Amp at solenoid Replace with same amperage fuse when necessary NOTICE DO NOT attempt to jump in line fuses with other objects other than the specified fuse s DO NOT increase the amperage rating of fuse Serious harm to the liftgate will result when standard prac...

Page 16: ...r Valve Body Closing Cylinder Pump Unit Relief Valve 2900 psi Filter Pump Flow Control Press Comp 1 0 gpm Port Port Port Flow Control Fixed 035 Locking Valve Main Cylinder Locking Valve Closing Cylinder Shuttle Valve Reservoir Tank Hydraulic Schematic Power Closing S1 S2 Open Close Valve Lift Lower Valve Motor ...

Page 17: ...e 2900 psi Filter Pump Flow Control Press Comp 1 0 gpm Port Port Port Flow Control Fixed 035 Locking Valve Main Cylinder Locking Valve Closing Cylinder Shuttle Valve Reservoir Tank Hydraulic Schematic Power Closing Green 12 Volt Selected Red High Pressure Blue Low Pressure Lower Function Lowering Function S1 Valve S1 S2 Motor Lift Lower Valve Open Close Valve ...

Page 18: ...alve 2900 psi Filter Pump Flow Control Press Comp 1 0 gpm Port Port Port Flow Control Fixed 035 Locking Valve Main Cylinder Locking Valve Closing Cylinder Shuttle Valve Reservoir Tank Hydraulic Schematic Power Closing Green 12 Volt Selected Red High Pressure Blue Low Pressure Open Function Open Function S2 Valve S1 S2 Motor Lift Lower Valve Open Close Valve ...

Page 19: ...lve 2900 psi Filter Pump Flow Control Press Comp 1 0 gpm Port Port Port Flow Control Fixed 035 Locking Valve Main Cylinder Locking Valve Closing Cylinder Shuttle Valve Reservoir Tank Hydraulic Schematic Power Closing Green 12 Volt Selected Red High Pressure Blue Low Pressure Lift Function M Lift Function Motor S1 Valve S2 S1 Lift Lower Valve Open Close Valve ...

Page 20: ...ve 2900 psi Filter Pump Flow Control Press Comp 1 0 gpm Port Port Port Flow Control Fixed 035 Locking Valve Main Cylinder Locking Valve Closing Cylinder Shuttle Valve Reservoir Tank Hydraulic Schematic Power Closing Green 12 Volt Selected Red High Pressure Blue Low Pressure Close Function M Close Function Motor S2 Valve S1 S2 Lift Lower Valve Open Close Valve ...

Page 21: ...oblem is in the pump and you need to replace pump and motor If gate still doesn t go down the problem is not in the pump or motor and other troubleshooting needs to be done to determine if the problems are in the raise and lower valve at the end of the cylinder or in the runners in the columns 21 ILM plus Series Main hydraulic line Vent Cap Platform is not lowering down ...

Page 22: ...ck ground screw at solenoid bracket if lose Then its recommend removing ground from solenoid bracket And install 5 16 X 1 2 course thread bolt in side of pump block marked GRD Controller fused connection at solenoid 15 amp fuse for controller power ...

Page 23: ...lease Valve Coil Test If one valve on cylinders are not opening up low voltage may be the cause A minimum of 10 V is necessary to properly energize each of the solenoid coils If the minimum voltage is present at both coils the coil may not be generating the magnetism needed to open the Release valve How to check coils for resistance Multimeter set OHM function Place test leads on coil nodes Readin...

Page 24: ...t Tools required for adjustment 13 mm wrench Allen wrench 5 32 Allen wrench Palfinger Part required for gauge connections 1 HYD gauge PD 3121327 1 Adaptor fitting PD 312329 1 Elbow fitting PD 75082871 Removing adjustment cap nut with 13 mm wrench Adjustment 5 32 Allen wrench Raise platform until secure in stored position with safety latch down Loosen allen wrench one turn Counter Clockwise while m...

Page 25: ...ems listed below Rails are not damaged crushed or pulled open Inside of rails are clean and free of any grease or non approved lubricants Inside of rails are smooth and free of any rust pitting paint overspray or weld spatter full length Runners are straight plastic pads in place clean not sticky not burnt from welding during install Bottoms of rails if cut free of slag and burrs and ground off sm...

Page 26: ...s are tight on adjusting anchors AF sprocket boxes are square and parallel to columns Deck support chains are adjusted for even tension left and right sides Sprockets should show signs on break in grease and roll freely this includes AF sprockets Sprockets and pins are checked for proper fit No sloppy sprockets no broken teeth Roller chains are free of binding and not seized Check entire length Ad...

Page 27: ...chedule will vary based on cycles load and environment We recommend motor oil 0W20 administered via a machinist style oil can Don t over do it a little goes a long way two or three squirts on to slide surfaces will last months in most cases Deck There are 2 grease fittings to maintain left and right main pivots Power Closing There are 2 grease fittings to maintain upper lower cylinder pivot points...

Page 28: ...g 2 for deck 2 for power closing Deck support chains and optional Cart Stops use light penetrating oil Hydraulic oil level in the power pack tank 2 to the top with deck on the ground see Alternative Fluids chart for recommended Hydraulic oils on Page 3 IN Columns optional use 0W20 motor oil Never use GREASE of any kind ...

Page 29: ...r Parts Asst Technical Support 609 587 4200 ext 126 b styer palfinger com James Ross Parts Asst 609 587 4200 ext 129 j ross palfinger com Sean Gettler Parts Supervisor 609 587 4200 ext 128 s gettler palfingr com Bob Hennessee General Manager 609 587 4200 ext 125 r hennessee palfinger com WEST COAST Cerritos CA 8 00am to 5 00pm PT Monday thru Friday Jorge Gallardo Asst Tech Support and Warranty Man...