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ILP
INSTALLATION MANUAL
& CHECK-OFF SHEET
ECN-M0247 Rev. 1.4, Date 07-03-2013 Part #90-0113-200
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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Summary of Contents for Palfinger ILP
- Page 1 INSTALLATION MANUAL & CHECK-OFF SHEET ECN-M0247 Rev. 1.4, Date 07-03-2013 Part #90-0113-200 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
Gate Overview and Components ..................... 5 General information: ........................ 6 Installation Dimensions ......................8 Installation Dimensions 800mm arm ILP – SQUARE TUBE MAIN FRAME ....9 4.1.1 Possible Mount Plate Modifications for Short Over Hang ......... 9 Bed Height Ranges: Unloaded Truck 800mm Arm – SQUARE TUBE ......10 Installation Dimensions 800mm arm ILP –... - Page 3 ABLE OF CONTENT Recommended Tools For Installation Metric Wrench Set Test Light ½” Impact & Sockets Small To Medium Bottle Jack Pry Bar Min. 250 Amp Welder Basic Screwdrivers Snap Ring Pliers Sm. Metric Socket Set Forklift or O/H Crane 3/8 Drill Motor Cutting Torch or Equiv.
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Page 4: Safety Information
Safety Information Safety Information This manual follows the Guidelines set forth in “ANSI Z535.4-2007” for alerting you to possible hazards and their potential severity. NOTICE 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 special instructions, steps, or procedures.) CAUTION without the safety alert symbol is used to address practices not related to personal injury. -
Page 5: Gate Overview And Components
Gate Overview and Components Gate Overview and Components Bed Extension Hydraulic Power Unit Mount Plates Roller Lift Cylinders Parallel Arm Platform Mount Frame Rubber Snubber Center of Gravity Lift Arm Figure 1 Liftgate overview with component description A liftgate contains three (3) main objectives: 1) Foldable platform with shackles and coil springs 2) Lift arm assembly with parallel arms and lift cylinder 3) Main frame with roll over assembly and power pack enclosure... -
Page 6: General Information
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) Final Check-Off-Sheet at rear of this manual MUST be filled out and kept in your records for future reference. - Page 7 Read and clearly understand manual BEFORE beginning ANY work Important!!! The basic rule of PALFINGER Liftgates ILP 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.
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Page 8: Installation Dimensions
Installation Dimensions Installation Dimensions No we l d No we l d Do n o t we l d a c r o s s t h e c o r n e r p o s t s a r e a s a r e a s Figure 2 Chassis Dimension sheet for special requests Revision 1.3... -
Page 9: Installation Dimensions 800Mm Arm Ilp - Square Tube Main Frame
Installation Dimensions Installation Dimensions 800mm arm ILP – SQUARE TUBE MAIN FRAME Ground „F“ *Mount Clearance End of Body to Bed Height Clearance Dimension Front of Mount Plate "F" Dim. Bed Height Ground Clearance Figure 3 Mounting dimensions 800mm arm... -
Page 10: Bed Height Ranges: Unloaded Truck 800Mm Arm - Square Tube
Installation Dimensions Bed Height Ranges: Unloaded Truck 800mm Arm – SQUARE TUBE Basic frame cut out and installation information ILP, (800 mm) 48" P/F Bedheights covered: 38", 43", 47", 51" and 53" 800 mm 31-1/2" 16-1/2" 17-1/2" 14" 12" 12"... -
Page 11: Installation Dimensions 800Mm Arm Ilp - Round Tube Main Frame
Installation Dimensions Installation Dimensions 800mm arm ILP – ROUND TUBE MAIN FRAME Ground „F“ *Mount Clearance Bed Height End of Body to Clearance Dimension Front of Mount Plate "F" Dim. Ground Clearance Figure 6 Mounting dimensions 800mm arm Mounting Dimensions NEVER exceed any of the dimensions from the STAY WITH THE „F“... -
Page 12: Bed Height Ranges: Unloaded Truck 800Mm Arm
Installation Dimensions Bed Height Ranges: Unloaded Truck 800mm Arm Basic frame cut out and installation information ILP - ROUND TUBE Bedheights covered: 38", 43", 47", 51" and 53" 800 mm 31-1/2" 16-1/2" 17-1/2" 13-1/2" 12" 12" 12" Min laden bed height 38"... -
Page 13: Installation Dimensions 900Mm Arm Ilp
Minimum-Maximum Dimensions Suggested Mounting Dimensions Minimum bed height is when truck/trailer is loaded to MAX GVW (all dimensions in inches) Mounting Dimensions ILP 54” (1375 mm) and 60" (1525 mm) platform with 900mm arm Bed Height F-Dimension Cut-out X Cut-out Y... -
Page 14: Bed Height Ranges: Unloaded Truck 900Mm Arm
Bed Height Ranges: Unloaded Truck 900mm Arm These dimensions are starting points. Your final dimensions may vary depending on actual installation F-Dim Basic frame cut out and installation information ILP 900 mm Arm (35") 54"Platform (900 mm) Bed heights covered: 45", 47", 51" and 55" 35-1/2"... -
Page 15: Chassis And Body Preparation
5 Chassis and Body Preparation Chassis and Body Preparation The ILP liftgate will require different mounting space requirements depending on floor heights. 1. Determine the correct frame cut out according to your specific bed height refer to Chapter 4.2 and 4.4. -
Page 16: Gate And Platform Installation
10. Check if wires and hoses are not in the liftgate operational areas during moving at the platform. Min. 8" Weld Overlap 1/4" Use second jack to level Underride Guard(ILFS)/ Rollover Wheel(ILP) 12 volt power may need to be connected to release pressure from Lift Cylinders (Down Function) Figure 13: Lift table and jack support Revision 1.3... - Page 17 6 Gate and Platform Installation PLATFORM WILL NOT TILT TO THE GROUND IF THESE WELDS ARE NOT REMOVED! Operator must continue to hold down button/toggle after lift arms touch ground to allow platform tip to tilt to the ground Knuckle is able to swing when platform touches ground with tacks removed Grind off tack welds from both knuckles (these are the only ones...
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Page 18: Gate Installation Using Liftarm Pins (Platform Not Installed)
6 Gate and Platform Installation Use alternative platform store stop method on installation with square cut frames. 3" Std channel Weld to chassis and/or long sill Set channel to contact platform when closed. Adjust (2) rubber snubbers to raise tight against channel Figure 17 Alternative frame modification Raise tip of platform to achieve 1 1/2“... -
Page 19: Platform Installation
6 Gate and Platform Installation Platform Installation 6.2.1 Never work under platform without safety supports 1. Support gate frame assembly on proper size and capacity horses or equiv. 2. Slide pins out to clear lift arm clevis (closest to center of platform) Do not slide so far that triangle block or spring fall out 4. -
Page 20: Tension On The Spring
6 Gate and Platform Installation Tension on the spring The torsion springs that assist the folding of the gate are shipped with no tension to aid the installation process. a. The dashed lines in Figure 18 show the shipping position of the spring arm. b. -
Page 21: Electrical Installation
7 Electrical Installation Electrical Installation When performing electrical installation, please be certain to install and secure everything in a way where it is not subject to damage from moving parts, sharp edges, exhaust systems, etc. If electrical parts (for example back lights) and wires are removed they have to be reinstalled and to be checked if they are working. -
Page 22: Up/Down Switch Installation
7 Electrical Installation UP/DOWN Switch Installation Determine location for fixed toggle switch on corner post in a way that the operator can view the platform and surrounding areas while operating the liftgate. Roll up door setup 7.3.1 Locate area on rear post of body where switch can be reached by operator from ground and body floor. - Approximately 24”... -
Page 23: Swing Door Setup
7 Electrical Installation Swing Door setup 7.3.2 Locate Area under bed extension or under body that will not be obstructed by doors when open 1. Drill 7/8” hole for control wire 2. Disconnect the three (3) connectors from up/down control wire 3. -
Page 24: On/Off Switch
7 Electrical Installation ON/OFF Switch Liftgate Cab Cut Off Switch MUST be installed and in clear view of driver. Place cab cut off switch (if applicable) in Corner Post clear view of the driver and within reach from the ground Shut Off Typical Trailer On/Off Installation... -
Page 25: Main Power Supply Wiring
7 Electrical Installation Main power supply wiring Liftgate Mount Frame Main Truck Batteries Circuit To Ignition Breaker Switch Ground Battery Ground Isolator (if applicable) Circuit Breaker Aux. Batteries (if applicable) (Third Battery Shown for heavy applications Only) Ground Figure 26 Main wiring with optional aux battery setup Revision 1.3 - 25 -... -
Page 26: Electrical Schematic Of Gate
7 Electrical Installation Electrical schematic of gate Figure 27 Electrical wiring schematic Revision 1.3 - 26 -... -
Page 27: Lubrication And Final Inspection
Lubrication and Final Inspection Lubrication and Final Inspection 1. Open platform and raise 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 repeat 4. Fold platform onto wheel and grease platform pins again 5. -
Page 28: Hydraulic Schematic And Decal Placement
Lubrication and Final Inspection Hydraulic Schematic and Decal Placement Functions: S1 and S2 = Release Valve for lowering function R1 and R2 = Flow Restrictor located inside hose adaptor on lift cylinder R5 = Restrictor Valve located in power pack Flow Divider is not activated, when fluid is going back into the power pack Access for pressure gauge... -
Page 29: Decal Placement And Inspection
Check Off Sheet 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 30 Check Off Sheet Figure 30 Decal Decal J Decal G Decal D Decal F Decal E Decal C - by circuit breaker at batteries Decal B Decal A Decal K Decal H - in the cabine or at On - Off at rear Figure 31 Decal placement Revision 1.3 - 30 -...
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Page 31: Check Off Sheet
Check Off Sheet Check Off Sheet JOB NO. GATE NO. VIN NO. OWNER'S MANUAL IN CAB ON-OFF SWITCH WORKING & DECAL IN PLACE WIRING 1. Power Cord Secured OPERATION 1. All Functions Operate On 2. Cables Not Rubbing Steel Up/Down Control, Hand Control 3.
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