Palfinger ILF 33 Installation Manual & Check-Off Sheet
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Palfinger ILF 33 Installation Manual & Check-Off Sheet

Palfinger ILF 33 Installation Manual & Check-Off Sheet

Liftgates 3300/4400/5500 lbs. capacity
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ILF 33 – 3300 lbs. Capacity
ILF 44 – 4400 lbs. Capacity
ILF 55 – 5500 lbs. Capacity
INSTALLATION MANUAL
& CHECK-OFF SHEET
09/16

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Summary of Contents for Palfinger ILF 33

  • Page 1 ILF 33 – 3300 lbs. Capacity ILF 44 – 4400 lbs. Capacity ILF 55 – 5500 lbs. Capacity INSTALLATION MANUAL & CHECK-OFF SHEET 09/16...
  • Page 2 Copyright © 2016 Palfinger Liftgates LLC. All rights reserved. Information in this document is subject to change without notice. Visit www.palfinger.com for up to date information and notifications. If you received this product with damaged or missing parts, contact Palfinger Liftgates at (888)-774-5844 Parts Order liftgateparts@palfinger.com...

  • Page 3: Table Of Contents

    General Overview of ILF Liftgate ..................... 12 Chassis and Body Preparation ....................14 Installation Dimensions ....................14 Chassis Cut Out ILF 33 ....................15 6.2.1 Installation Dimensions ILF 44 and ILF 55 ............16 Chassis Cut Out ILF 44/55 .................... 17 Frame Cap ........................
  • Page 4 ILF 33/44/55 Installation Manual Lubrication ..........................50 Hydraulic Schematic ........................ 51 Decal Placement and Inspection ..................... 52 Final Inspection Check List ..................... 54 Company Information: Company Name: Advisor Name: Trailer Year Make & Model: Liftgate Information: Liftgate Serial Number: Liftgate Model Number:...

  • Page 5: Manual Updates For V1.1

    ILF 33/44/55 Installation Manual Manual Updates for v1.1  Updated Section 7.8: Foot control installation  Updated Section 8.2: Decal placement Rev 1.1...

  • Page 6: Safety Information

    ILF 33/44/55 Installation Manual Safety Information This manual follows the guidelines set forth in “ANSI Z535.4-2007” for alerting you to possible hazards and their potential severity. This is the safety alert symbol. It is used to alert you to potential personal injury hazards.

  • Page 7: Important Information

    Always Ground closest to your welding point to prevent arcing through moving parts or electrical parts.  Contact PALFINGER Liftgates for Special Installations not covered in this Installation Manual.  Do not paint cylinder shafts or nylon bearings (Use non-chlorinated brake cleaner to remove over spray) ...
  • Page 8 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 888-774-5844. You can also contact PALFINGER Liftgates by fax (562) 924-8318 or on the internet at www.palfinger.com For technical support, contact PALFINGER Liftgates or an authorized PALFINGER service center.

  • Page 9: Important Dimensions

    Mounting Notes: Read and clearly understand manual BEFORE beginning ANY work. The basic rule of PALFINGER Liftgates‟s ILF installation is to lift mount frame to achieve MAXIMUM ground clearance WITHOUT exceeding Min “F” dimension. Recommended Tools...

  • Page 10: Dimension Sheet

    ILF 33-44-55 Installation Manual Dimension Sheet Rev 1.1...
  • Page 11 ILF 33-44-55 Installation Manual Rev 1.1...

  • Page 12: General Overview Of Ilf Liftgate

    ILF 33/44/55 Installation Manual General Overview of ILF Liftgate Extension Mount Plates Mount Frame Control Bumper Hydraulic Parting Power Unit Wheel Lift Arm Tilt Arm Aluminum Platform ILF 33 Extension Mount Plates Mount Frame Control Bumper Hydraulic Parting Power Unit...
  • Page 13 ILF 33/44/55 Installation Manual Boxed Items Included with Liftgate for Installation Heat Shrink, ø1/2" x 3"L 1 pc Decal Kit 15 pcs Installation Manual Owner's Manual 1 pc 1 pc Butt Splice In-Line Fuse, 20 Amp 1 pcs 1 pcs Ring Connector, 3/8"...

  • Page 14: Chassis And Body Preparation

    Minimum bed height is when truck/trailer is loaded to MAX GVW "K" Mount Clearance (Reference) Sill "F" Dim. Bed Height Max. 62" Min. 46" "G" Ground Clearance ILF 33 Mounting Dimension Table Bed Height (Loaded) Dim. Dim. Dim. (Ref.) 62“ 33“ 20“ 29“ 58“...

  • Page 15: Chassis Cut Out Ilf 33

    ILF 33/44/55 Installation Manual Chassis Cut Out ILF 33 These dimensions are starting points due to variation of installations. The final dimensions may vary depending on actual installation F-Dim. 1. Determine the correct frame cut out according to your specific bed height. With long overhangs it is even more important to maintain min F = Max ground clearance, Fig.

  • Page 16: Installation Dimensions Ilf 44 And Ilf 55

    ILF 33/44/55 Installation Manual 6.2.1 Installation Dimensions ILF 44 and ILF 55 IMPORTANT: Always use the smallest F-dim possible for best ground clearance (Don‟t exceed max. ground clearance) Minimum bed height is when truck/trailer is loaded to MAX GVW "K"...

  • Page 17: Chassis Cut Out Ilf 44/55

    ILF 33/44/55 Installation Manual Chassis Cut Out ILF 44/55 These dimensions are starting points due to variation in installations. The final dimensions may vary depending on actual installation F-Dim. 3. Determine the correct frame cut out according to your specific bed height. With long overhangs it is even more important to maintain min F = Max ground clearance, Fig.

  • Page 18: Frame Cap

    Capping the frame cut outs is recommended to help protect the liftgates platform from being damaged, Fig. 5. NOTE: Palfinger Liftgates does not supply cap materials. All material must be supplied by end user. 1. Suggested components: 2”x3”x3/16” angle, and ¼” flat bar stock. Cut material to size.
  • Page 19 ILF 33/44/55 Installation Manual NOTES Rev 1.1...

  • Page 20: Bed Extension Installation

    ILF 33/44/55 Installation Manual Bed Extension Installation NOTE: Standard bed extension measures 102” wide, for 96” vehicles, trim each end, Fig. 6. 1. Center bed extension to vehicle body. Lay channels flush with the bed extension, sill, and floor. If tack welding the channels, tack weld channels or angles to bed extension and sill.
  • Page 21 ILF 33/44/55 Installation Manual Top of Bed Extension Do Not Welding Area Weld Area 3/16" 4-10 Fig. 8 Do Not Weld Area Bottom of Bed Extension Welding Area 4-10 3/16" Weld-On Bed Extension Welding Locations Rev 1.1...

  • Page 22: Dock Bumper Installation - Weld On (Optional)

    ILF 33/44/55 Installation Manual Dock Bumper Installation – Weld On (Optional) Dock Bumper 1pc Curb Side 1pc Street Side Dock Bumper Strut Brace 1pc Curb Side 1pc Street Side Support Channel 2 pcs Steps: 1. Dock Bumper: Position the dock bumper against the bed extension; make sure everything is squared vertically and horizontally.
  • Page 23 ILF 33/44/55 Installation Manual 2. Dock Bumper Struts: Before welding the struts and support channels, make sure the channels are properly adjusted for optimum installation. Position the support channels perpendicular to a minimum of three of the vehicles cross members, move the channel horizontally for adjust if necessary, Fig. 10. Use clamps or similar devices to hold the support channels in place.

  • Page 24: Liftgate Installation (Truck)

    Prior to beginning installation, assure the vehicle is on a leveled surface. NOTE: The installation process for an ILF 33, ILF 44, and ILF 55 is the same for all gates. For illustration purposes, an ILF 44 is shown.
  • Page 25 ILF 33/44/55 Installation Manual 2. Raise Platform: Clamp 3” channels over the bed extension and align the front edge of the platform, to the back edge of the bed extension, Fig. 12. Maintain the top of the platform flush to the bed extension (channel).
  • Page 26 ILF 33/44/55 Installation Manual Pull out power tray before welding. Power Tray is located inside the mount tube and can be accessed through the curb side of the mount tube. 4. Pull out the power pack tray approximately 20” out of the mount tube by removing the bolt on the curbside and detach the ground strap and control power connector from the tray, Fig.
  • Page 27 ILF 33/44/55 Installation Manual 6. Place the mount tube in the predetermined position, keeping the given maximums and minimums dimensions in mind. Support the mount tube using a rolling floor jack or a similar device to position the mount tube and clamp plates. Make sure the mount tube is squared 90-degreed, vertically and horizontally, to the truck frame.
  • Page 28 ILF 33/44/55 Installation Manual 7. Proceed to the electrical installation, Section 9. To adjust the tilt cylinder during installation, disconnect the B-15 sensor at J41 on the control board. Remember to reconnect the B-15 sensor back into J41 on the control board after any adjustments are done, Fig.
  • Page 29 ILF 33/44/55 Installation Manual 9. After verification of everything being aligned, proceed to welding the unit completely. Weld 100% with ¼” welds against the frame and both sides of the plates against the mount frame. Before running the unit through its cycle, make sure that the In-Cab Switch is in the “ON”...

  • Page 30: Liftgate Installation (Trailer)

    ILF 33/44/55 Installation Manual Liftgate Installation (Trailer) Warning: Never work or place yourself under unsupported platform High heat and spatter from welding can damage components. Make sure components such as hoses, lines, and wires are clear of or protected from heat and spatter caused by welding.
  • Page 31 Use a minimum of 8” overlap between the mount plates and sub-frame channel. Clamp mount plates to sub-frame to prevent any misalignment before welding. Rear View of Trailer Sub-Frame Channel Recommended Support Plates along sub-frame channel for strength (Not supplied by Palfinger) Mount Mount Plate Plates Street Side Mount Plate 3/16" 8.00"...
  • Page 32 ILF 33/44/55 Installation Manual To adjust the tilt cylinder during installation, disconnect the B-15 sensor at J41 on the control board. Remember to reconnect the B-15 sensor back into J41 on the control board after any adjustments are done B15 PLATFORM 4.
  • Page 33 ILF 33/44/55 Installation Manual 5. After verification of everything being aligned, proceed to welding the unit completely. Weld 100% with ¼” welds against the frame and both sides of the plates against the mount frame. Before running the unit through its cycle, make sure that the In-Cab Switch is in the “ON”...

  • Page 34: Operation Of B-15 Sensor

    ILF 33/44/55 Installation Manual Operation of B-15 Sensor The B-15 Sensor allows the platform to tilt, up or down, once it has reached a minimum height off the ground, Fig. 19. The sensor will not allow the platform to tilt after a certain height off the ground for safety purposes.

  • Page 35: Operation Of B-13 Sensor

    ILF 33/44/55 Installation Manual Operation of B-13 Sensor The B-13 Sensor allows the lift arm to, Fig. 20: 1. Raise platform approximately 12-15” off ground and verify platform is level (tilt if necessary). 2. Loosen lock bolt and set sensor level with platform/ground (verify colored side of sensor is out).

  • Page 36: Electrical Installation

     Any deviation from PALFINGER Liftgates’s recommended power setup will void warranty and product liability unless you have a written confirmation by PALFINGER Liftgates that allows you to do specific changes.  Prior to starting electrical installation insure that the liftgate batteries are fully charged. 12.6V for Flooded Acid Batteries, and 12.8V for AGM Batteries.

  • Page 37: Wire Crimping

    ILF 33/44/55 Installation Manual Wire Crimping All grounding surfaces MUST be cleaned, prepped, and sealed per this manual. “Cut to size” cables MUST be properly crimped and sealed as factory supplied. All connections MUST be dressed with dielectric grease or equivalent sealer.

  • Page 38: Circuit Breaker Installation

    ILF 33/44/55 Installation Manual Circuit Breaker Installation 1. Mount the circuit breaker securely in battery box or at positive battery terminal using the buss bar, Fig. 21. 2. Connect the liftgate 2 Gauge cable to AUX stud on the circuit breaker.

  • Page 39: Cable Routing

    ILF 33/44/55 Installation Manual Cable Routing 1. Route all cables along the wooden spacer and through the outside of the U-bolts. 2. Secure the routed wire every 12” with insulated wire clamps or staples against the wooded spacer(s). 3. The use of wire loom is highly recommended to protect and facilitate cable routing. Wire loom not supplied.

  • Page 40: Main Power Connections

    ILF 33/44/55 Installation Manual Main Power Connections Wires #2 and #4 Wires #2 and #4 go to postitive (+) go to postitive (+) *In-Line *In-Line Fuse Fuse Wires #1 and Gr/Yl Wires #1 and Gr/Yl go to ground (-) go to ground (-)

  • Page 41: On-Off Switch Installation (Truck Application)

    ILF 33/44/55 Installation Manual On-Off Switch Installation (Truck Application) 1. Route the J11 wire harness from the control box to the inside of the cab. 2. Place the switch where it can conveniently be seen and reached from the driver’s seat as well as from the ground, Fig.

  • Page 42: On-Off Switch Installation (Trailer Application)

    ILF 33/44/55 Installation Manual On-Off Switch Installation (Trailer Application) 1. Position the mounting brackets as close as possible to rear of the vehicle where the operator will have a clear view of the platform/load, Fig. 24. Make sure the mounting brackets and control box do not interfere with the platform and that the control box does not protrude beyond the width of the vehicle body.
  • Page 43 ILF 33/44/55 Installation Manual ON/OFF Switch Wiring On a trailer installation the control port J11 has to be connected with an on/off toggle switch connecting 2 and 4 on port J11 together. NOTE: The Circuit Board is located inside the 7” x 7” mount tube of the liftgate assembly on the curb side.

  • Page 44: Remote Hand Control Installation

    ILF 33/44/55 Installation Manual Remote Hand Control Installation Hand Controls are NOT weatherproof and are to be stored inside the vehicles body in holster or in weatherproof box (optional). For “Reefer” and Flatbed installations, a “plug & socket” installation is recommended.
  • Page 45 ILF 33/44/55 Installation Manual Plug and Socket Installation for Reefer or Flatbed Trucks (Optional): 3. The socket can be installed in varies locations depending on user preference. The dock bumper strut has pre-drilled holes for the socket to mount, or it can also be installed where the end user feels most convenient.

  • Page 46: Foot Control Installation (Optional)

    ILF 33/44/55 Installation Manual Foot Control Installation (Optional) 1. Measure and drill two ø2” holes on the main section of the platform (curb side). Use the dimensions shown below. 6-3/4"" Front of Platform 10-1/2" Drill 10" Steel Main ø2" Section Tip Section 2.
  • Page 47 ILF 33/44/55 Installation Manual When routing the cable, make sure to allow cable slack to prevent any damage to the cable(s). 3. Use crimp terminals on the end of the wires. Insert the Front Foot Control Harness wires to pins 5, 4 on the J3 plug.

  • Page 48: Electrical Schematic

    ILF 33/44/55 Installation Manual Electrical Schematic Electrical Schematic Rev 1.1...

  • Page 49: Control Board Codes

    ILF 33/44/55 Installation Manual 9.10 Control Board Codes B15 PLATFORM WARNING FOOT B13 LIFT ARM GROUND for PC BOARD LIGHTS CONTROL (green/yellow and black # 1) CAB CUT OFF SWITCH CONTROL POWER PACK POSITIVE for PC BOARD HAND (black #2 to 2...

  • Page 50: Lubrication

    ILF 33/44/55 Installation Manual Lubrication 1. Lower the platform to the ground. 2. Remove red protector caps from each component. Lubricate, grease, and oil per diagram below. 3. Cycle platform up and down several times. Lubricate and grease all points again.

  • Page 51: Hydraulic Schematic

    ILF 33/44/55 Installation Manual Hydraulic Schematic Functions: S1 and S2 = Release Valve for lowering function S3 and S4 = Release Valve for tilt down function R1 and R2 = Flow Restrictor located inside hose adaptor on lift cylinder R3 and R4 = Flow Restrictor located inside hose adaptor on tilt cylinder...

  • Page 52: Decal Placement And Inspection

    ILF 33/44/55 Installation Manual Decal Placement and Inspection For operator safety, all decals appearing in “Decal Kit” must be in a conspicuous place on control side of liftgate. This is typically a combination of decals on the liftgate and truck or trailer body. Please make sure to place the maximum capacity decal (C) on driver and curb side.
  • Page 53 ILF 33/44/55 Installation Manual Curb Side Decal - B Decal - A G, K Decal - D Decal - C Driver Side Decal - F Decal - E Decal - H Decal - G Decal - J Decal - I...

  • Page 54: Final Inspection Check List

    ILF 33/44/55 Installation Manual Final Inspection Check List Liftgate failure or malfunction could result in property damage, personal injury or death if you fail to check each of the following items listed. DO NOT USE the liftgate if any of the following points are NOT verified and checked.
  • Page 55 ILF 33/44/55 Installation Manual Rev 1.1...

This manual is also suitable for:

Ilf 55Ilf 44

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