Table of Contents
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ILK
INSTALLATION MANUAL
& CHECK-OFF SHEET
ECN-M1508 Rev. 1.6, Date 09-21-20 Part #90-0413-200
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
www.palfinger.com
Visit our website at
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
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Table of Contents
Summary of Contents for Palfinger ILK 22
- Page 1 INSTALLATION MANUAL & CHECK-OFF SHEET ECN-M1508 Rev. 1.6, Date 09-21-20 Part #90-0413-200 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 www.palfinger.com Visit our website at...
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Page 2: Table Of Contents
Swing door applications ....................15 Gate and Platform Installation ....................16 Sill Preparation ......................16 Installation with mounting fixture ................... 16 Bolt-On Mount Plate Installation – ILK 22/33/44/55 ............19 5.3.1 Mount Plate Installation ................... 20 Platform Installation ...................... 23 5.4.1... -
Page 3: Manual Updates
ILK 22/33/44/55/66 NSTALLATION ANUAL Lubrication and Final Inspection ..................... 43 Decal Placement and Inspection ................... 44 Check Off Sheet ........................47 Manual Updates Revision Description • Updated mount plate installation instructions, Section 5.3 V1.6 Recommended Tools for Installation Metric Wrench Set... -
Page 4: Important Notes
11. Verify that pin lock bolts are tight 12. Grease all pivot points 13. Verify that ALL decals are placed properly (Contact PALFINGER Liftgates replace any missing de- cals) Final Check-Off-Sheet at rear of this manual MUST be filled out and kept in your records for future reference. - Page 5 Read and clearly understand manual BEFORE beginning ANY work Important!!! The basic rule of PALFINGER Liftgates ILK installation is to raise mount frame to achieve MAXIMUM ground clearance WITHOUT exceeding Min “F” dimension. Refer to mounting tables and determine the proper [S] dimension. If the sill is greater than what’s allowed, the sill has to be notched and capped to achieve original strength.
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Page 6: Gate Overview And Components
ILK 22/33/44/55/66 NSTALLATION ANUAL Gate Overview and Components 3 Button Hand control Mount frame Tilt Cylinder (outside of the Frame) Serial Tag Lift Arm Lift Cylinder Control box Rear bumper Circuit Board Center of Gravity of (behind cover) maximum load... - Page 7 ILK 22/33/44/55/66 NSTALLATION ANUAL NOTES Revision 1.6 - 7 -...
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Page 8: Dimension Sheets
ILK 22/33/44/55/66 NSTALLATION ANUAL Dimension Sheets Truck Chassis Dimension Sheet Customer Information Liftgates Information: Quote#/SO#:____________________________________________________ Model Company:______________________________________________________ Capacity Phone:_________________________________________________________ Platform Size Email: _________________________@______________________________ Platform Material Truck Information Type of Body Truck Specifications: Type of Rear Door (check applicable) (check applicable) - Page 9 ILK 22/33/44/55/66 NSTALLATION ANUAL Trailer Chassis Dimension Sheet Customer Information Liftgates Information: Quote#/SO#:____________________________________________________ Model: Company:______________________________________________________ Capacity: Phone:_________________________________________________________ Platform Size: Email: _________________________@______________________________ Platform Material: Trailer Information Type of Body Trailer Specifications: Type of Rear Door (check applicable) (check applicable) Manufacturer: Flip-Up (ex.
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Page 10: Installation Dimensions Ilk22 And Ilk 33- "Low Mount" 700 Mm Arm
25 26 27 28 29 30 31 32 33 34 35 Figure 3.1: ILK22 and ILK33 Installation table Part number for ILK 22 Mounting Fixture: 1-00015, Part number for ILK 33 Mounting Fixture: 1-00016 ILK22 comes with 2 different mount plates (bolted or welded) MINIMUM bed height is defined as truck/trailer loaded to MAX GVW Revision 1.6... -
Page 11: Installation Dimensions Ilk33, Ilk44, Ilk55 800Mm Arm
ILK 22/33/44/55/66 NSTALLATION ANUAL Installation Dimensions ILK33, ILK44, ILK55 800mm arm IMPORTANT: Always use the smallest F-dim possible for best ground clearance (don’t exceed max. ground clearance!) K-dim. - Min 25" Max 35" 7" Max ground clearance 21" (never exceed max) Min ground clearance 10"... -
Page 12: Installation Dimensions Ilk66 900Mm Arm
ILK 22/33/44/55/66 NSTALLATION ANUAL Installation Dimensions ILK66 900mm arm IMPORTANT: Always use the smallest F-dim possible for best ground clearance (do not exceed max. ground clearance!) K-dim. - Min 32" Max 42" 7.5" Max ground clearance 22.5" (never exceed max) Min ground clearance 11.5"... -
Page 13: Chassis And Body Preparation For Special Applications
ILK 22/33/44/55/66 NSTALLATION ANUAL Chassis and Body Preparation for special applications Flip-Up door & Full-door seal kit installation 1. Install ½” x 1-1/2” HR flat bar to the lower rear body seal Gasket Channel (Full Door Kit Only) Gasket Channel 1/2"... - Page 14 ILK 22/33/44/55/66 NSTALLATION ANUAL 3. Install gasket channels on rear vertical body posts to make contact with the platform surface. Gasket must NOT make contact with platform edge caps. Doing so will cause leaks. 4. For full door seal kits install gasket channel along header at edge of platform...
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Page 15: Swing Door Applications
ILK 22/33/44/55/66 NSTALLATION ANUAL Swing door applications A bridge kit is recommended for the usage of an ILK liftgate behind swing doors. Due to the shifted pivot points all welding and cut out points have to be shifted according- Top View 3"x4.1 Channel... -
Page 16: Gate And Platform Installation
1. Locate and mark out the center of the rear body or bed sill. 2. Attach the PALFINGER Liftgates mounting fixture centered to the sill by tack welding it in place. (The mounting fixture must be ordered separately from PALFINGER Liftgates. Once purchased it can be used over and over) 3. - Page 17 ILK 22/33/44/55/66 NSTALLATION ANUAL Mount Fixture Mount Fixture as shown Lift Arm Maintain Parallel with 90.00° Truck Body floor Figure 5.2: Mount frame alignment with fixture 6. With the mount tube held in place, position the mount plates over tube and against truck frame. Po- sition them with angle facing to back of truck and clamp them to truck frame.
- Page 18 ILK 22/33/44/55/66 NSTALLATION ANUAL 9. Tack weld mount plates to mount tube with a minimum of three 2” and three 2” welds to the truck frame. Before finishing up all welding we recommend doing the electrical installation (see 6, Page 30) and platform installation (see 5.4, Page 23) to make sure that everything aligns like it should.
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Page 19: Bolt-On Mount Plate Installation - Ilk 22/33/44/55
ILK 22/33/44/55/66 NSTALLATION ANUAL Bolt-On Mount Plate Installation – ILK 22/33/44/55 IMPORTANT: When drilling into the vehicles C-Channels, make sure to observe the vehicle manufacture’s guidelines and recommendations before drilling. When installing the mount plates on a C-Chassis use the following amount of bolts listed below... -
Page 20: Mount Plate Installation
Mount Plate Installation 5.3.1 ILK 22 Bolted Mount Plates 1) Set up mount plates (2) on top of mount frame (1) 2) Connect mount plate (2) to mount frame (1) with Hex head bolts (3), lock washer (4) and (5) square washer. - Page 21 ILK 22/33/44/55/66 NSTALLATION ANUAL ILK 33 Bolted and Clamped Plates Installation 1. Insert the mount plates (2) with the bolts (3) onto the mount frame (1) and secure the mount plate (4) hook to the mount frame. 2. Tighten the M20 hex nuts (5) onto the bolts (3) to secure the mount plate (2) to the mount frame U-section (6).
- Page 22 ILK 22/33/44/55/66 NSTALLATION ANUAL ILK 44/55 Bolted Plates 1. Install the preinstalled bolts on the mount plate (2) on mount frame (1). Install nuts (7) but do not tighten completely. Hook the front end of the mount plate (2) to the mount frame bracket (3).Install locking bracket (4) in between mount plates (2) and mount frame (3).
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Page 23: Platform Installation
ILK 22/33/44/55/66 NSTALLATION ANUAL Platform Installation • If power pack is still removed from mount tube for welding, reconnect the ground cable and pow- er connection. Do not push back in, welding is not finished!!!!!! Attention: check all PC-Board connections for tightness Attach platform to liftarm 5.4.1... - Page 24 ILK 22/33/44/55/66 NSTALLATION ANUAL Wrench Sizes for Tilt Cylinder Adjustments Gate Model Piston ILK 22 29MM 29MM ILK 33 50MM 36MM ILK 44-55 65MM 42MM ILK66 71 MM 50 MM How to adjust the tilt cylinders: 1. Raise the gate all the way up against the truck body.
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Page 25: Installation Without Mount Fixture
ILK 22/33/44/55/66 NSTALLATION ANUAL Installation without mount fixture 1. Connect platform to lift arms using short pins. 2. Tie tilt cylinders with rope or wire to lift arm to avoid dragging on the ground. 3. Support platform with forklift, overhead crane or similar device. -
Page 26: Setting And Operation Of B-15 Sensor
ILK 22/33/44/55/66 NSTALLATION ANUAL Setting and Operation of B-15 Sensor 1. Mount the platform sensor B-15 to the right-hand side of the platform as shown in Fig.4.4. Make sure to loop wire around to give it enough slack in normal operation and route clear of any pinch points. -
Page 27: Setting And Operation Of B-13 Sensor
ILK 22/33/44/55/66 NSTALLATION ANUAL Setting and Operation of B-13 Sensor 1. Raise platform approx. 8” – 10” off ground and verify platform is level (tilt if necessary) 2. Loosen lock bolt and set sensor level with platform surface/ground (verify colored side of sensor is out, plastic housing is facing to lift arm) 3. -
Page 28: Installation Of Left And Right Up Stops
ILK 22/33/44/55/66 NSTALLATION ANUAL Installation of left and right Up Stops Install the liftarm up stop so it is positioned in a way that it stops the liftarm when the platform is level with the floor of the truck Weld to C/M's... -
Page 29: Fork Lift Locks Installation For Re-Enforced Platforms
100% of the area around mount tube and around frame on both sides of plates. The plates must have a minimum of 8” of overlap on the frame. PALFINGER Liftgates recommends adding ¼” flat bar or plate to the top of mount plates if needed to tie Liftgate mount plates to body stringer. -
Page 30: Electrical Installation
ILK 22/33/44/55/66 NSTALLATION ANUAL Electrical Installation When performing electrical installation, always install and secure everything in a way where it is not subject to damage from moving parts, sharp edges, exhaust systems, etc. Never exceed rating of existing fuses located at the battery and control board at the pump... - Page 31 ILK 22/33/44/55/66 NSTALLATION ANUAL Wires #2 and #4 go to postitive (+) *In-Line Fuse Wires #1 and Gr/Yl go to ground (-) Resetable Circuit Breaker Auxiliary Batteries Ground 2GA. Liftgate Power Cable 4-Conductor Control Power Cable from Control Board *In-Line ATC Fuse: 20 Amp. Replace with same amperage fuse when necessary.
- Page 32 ILK 22/33/44/55/66 NSTALLATION ANUAL Breaker Installation (Fig. 6.1) 1. Determine location for fixed control box; locate it in a way that the operator can view the platform and surrounding areas while operating the liftgate. Also, locate in a way where the lid does not ex- tend outside the van body when open.
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Page 33: On-Off Switch Installation Truck Application (In Cab)
ILK 22/33/44/55/66 NSTALLATION ANUAL Always connect 4 wire harnesses directly to Truck/Trailer Battery. On-Off Switch Installation Truck Application (In Cab) Install the cab shut-off switch inside the cab. Locate it where it can conveniently be seen and reached from the driver’s seat as well as from the ground. -
Page 34: On-Off Switch Trailer Application
ILK 22/33/44/55/66 NSTALLATION ANUAL On-off Switch Trailer application On a trailer installation the control port J11 has to be connected with a on off toggle switch connecting 2 and 4 on port J11 together. OPERATING INSTRUCTIONS • To operate this liftgate read and understand the Tilt operating decals and manuals. -
Page 35: Remote Hand Control Installation
Remote Hand Control Installation Hand Controls are NOT weatherproof and have to be stored inside body in holster or in weatherproof box (PALFINGER Liftgates option). For “Refer”, Flatbed installations or stored in cab solutions we recommend “plug & socket” option. -
Page 36: Plug And Socket Application Setups
ILK 22/33/44/55/66 NSTALLATION ANUAL Plug and Socket application setups 5-Pin Socket/Plug Connectors Control Board Hand Held Remote Power LED Socket Plug 5.2 (Up) 5.2 (Up) Yellow 4(Hot) 3.2 (Tilt Up) 3.2 (Tilt Up) 4.3(Hot) Green/Yellow White 6.2 (Down) 14.2 (Tilt Down) 6.2 (Down) - Page 37 ILK 22/33/44/55/66 NSTALLATION ANUAL 6-Pin Socket/Plug Connectors Control Board Hand Held Remote Power LED Socket Plug 6.2 (Down) 6.2 (Down) Brown Not in Use Not in Use 14.2 (Tilt Down) 4 (Hot) 14.2(Tilt Down) 4.3(Hot) Green Green/Yellow 3.2 (Tilt Up) 5.2 (Up)
- Page 38 ILK 22/33/44/55/66 NSTALLATION ANUAL Hella 7-Pin Socket Connectors (5 Wire) Control Board Hand Held Remote plus Not in Use Not in Use 4 (Hot) 4.3 (Hot) 6.2 (Down) Green/Yellow 6.2 (Down) 5.2(Up) 5.2 (Up) 14.2(Tilt Down) 14.2 (Tilt Down) Yellow Green 3.2 (Tilt Up)
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Page 39: Foot Control Installation
ILK 22/33/44/55/66 NSTALLATION ANUAL Foot Control installation After installing the platform, connect the wiring harness from the platform to the connections at the liftarm. (see page 24). Each foot switch has a hot wire (#4) on plug J3. Switch (1) connects in addition to port #5 on J3;... -
Page 40: Wiring Diagrams
ILK 22/33/44/55/66 NSTALLATION ANUAL Wiring Diagrams Figure 6.2: Electrical schematics Revision 1.6 - 40 -... - Page 41 ILK 22/33/44/55/66 NSTALLATION ANUAL WARNING B15 PLATFORM 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 REMOTE and black # 4 to 27)
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Page 42: Hydraulic Schematic
ILK 22/33/44/55/66 NSTALLATION ANUAL 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 43 ILK 22/33/44/55/66 NSTALLATION ANUAL Lubrication and Final Inspection 1. Open platform and lift gate to bed level 2. Remove red caps, apply grease until grease begins to flow from bushing ends 3. Lower platform to ground and grease left over grease zerks.
- Page 44 ILK 22/33/44/55/66 NSTALLATION ANUAL Decal Placement and Inspection For operator’s safety, all decals appearing in “Decal Kit” must be in a conspicuous place on control side of liftgate to be read by operator. This is typically a combination of decals on the liftgate and truck body.
- Page 45 ILK 22/33/44/55/66 NSTALLATION ANUAL Decal K Decal J Decal C Decal A Decal H Decal F Decal B Aluminum operation plate for foot control 3”x4”, P-1341966 Decal G (on the back of the platform; visible Decal D - in the truck cab or...
- Page 46 ILK 22/33/44/55/66 NSTALLATION ANUAL 56" Revision 1.6 - 46 -...
- Page 47 This must be filled out and kept for your records. A copy of this sheet must be present- This must be filled out and kept for your records. A copy of this sheet must be ed to PALFINGER Liftgates for any warranty compensation. presented to Interlift for any warranty compensation Revision 1.6...