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ILU
INSTALLATION MANUAL
& CHECK-OFF SHEET
ECN-M0257 Rev. 1.5, Date 07-15-2013 Part #90-1313-200
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 ILU 40
- Page 1 INSTALLATION MANUAL & CHECK-OFF SHEET ECN-M0257 Rev. 1.5, Date 07-15-2013 Part #90-1313-200 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
ABLE OF CONTENTS ABLE OF CONTENTS ..........................2 ABLE OF CONTENTS Safety Infromation ........................5 Important Notes: ........................6 Chassis Dimension Sheets ...................... 8 Installation Dimensions ......................9 General Bed Height Ranges for ILU liftgates..............10 Chassis and Body Preparation ..................11 4.2.1 Mount frame clearance .................. - Page 3 Figure 1 Trailer dimension sheet ......................... 8 Figure 2 Truck dimension sheet ........................8 Figure 3 Installation Drawing - provided by PALFINGER Liftgates engineering department ......9 Figure 4 Mounting clearance ........................11 Figure 5 Sill cut-out dimensions - rear view ....................12 Figure 6 Sill cut-out –...
- Page 4 ABLE OF CONTENTS Recommended Tools For Installation Metric Wrench Set Basic Screwdrivers Pliers Wire Crimp Pliers Test Light Snap Ring Pliers Hammer Metric Allen Set 1.5mm-10mm ½” Impact & Sockets Sm. Metric Socket Set Assorted Drill Bits Floor Jack or Equiv. Sm.
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Page 5: Safety Infromation
1 Safety Infromation Safety Infromation This manual follows the Guidelines set forth in “ANSI Z535.4-2007” for alerting you to possible hazards and their potential severity. ! DANGER indicates an imminently hazardous situation which, if not avoided, will result in death or serious injury. -
Page 6: Important Notes
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 Mounting Notes: Read and clearly understand manual BEFORE beginning ANY work Important!!! The basic rule for installing an ILU PALFINGER Liftgate is to MOUNT THE FRAME AS HIGH AS POSSIBLE to achieve MAXIMUM GROUND CLEARANCE and MINIMIZE THE “F” DIMENSION.
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Page 8: Chassis Dimension Sheets
3 Chassis Dimension SheetsChassis Dimension Sheets Chassis Dimension Sheets Trailer Chassis Dimension Sheet Fill out and send to Interlift if specific install drawing is needed A= Bedheight, top of floor to even ground..B= Top of floor to bottom of trailer cross member..C= Rear sill height, top of floor to bottom of buck plate.. -
Page 9: Installation Dimensions
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. -
Page 10: General Bed Height Ranges For Ilu Liftgates
4 Installation Dimensions 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” Revision 1.5 - 10 -... -
Page 11: Chassis And Body Preparation
4 Installation Dimensions Chassis and Body Preparation Mount frame clearance 4.2.1 - Determine the correct mounting clearance according to your specific lift and chassis. - With long overhangs it is even more important to maintain Max ground clearance. o GROUND CLEARANCE = BOTTOM OF LIFTGATE FRAME TO GROUND - Determine if you need to move chassis U-bolts or if you have any other interferences, then proceed with installing the liftgate slide rails to the frame IMPORTANT (Truck Installation):... -
Page 12: Rear Sill Preparation
4 Installation Dimensions Rear sill preparation 4.2.2 To assure that the gate is reaching the body floor, you need to cut out the rear sill of your truck/trailer. • If sill is less than 4“ high No sill cut out needed •... - Page 13 4 Installation Dimensions • On trailers, you have to check the eyebrow clearance, and in case of interference cut eyebrow down until platform clears. • The eyebrow cut out can be done when gate and platform are installed and you raise up gate for the first time.
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Page 14: Gate Installation
5 Gate Installation Gate Installation Never work under mount frame or platform without safety supports Slide rail bracket installation ADD STEEL BACKER PLATE IF MOUNT BRACKET CAN NOT BE WELDED 100%. Figure 7 Slide rail installation 1) Make sure the specific install drawing sent with the liftgate matches the truck and gate you are about to install. -
Page 15: Liftgate Attachment
5 Gate Installation Liftgate attachment Figure 8 Liftgate installation to previous installed rails 1) Slide liftgate main frame assembly into previous installed slide rails. 2) Connect pin in front of push-pull cylinder to bracket towards truck cabin. Figure 9 platform attachment 3) Connect platform to frame by using supplied pins and lock bolts 4) Connect lift arm to inside clevis holes. -
Page 16: Control Power Wiring Setup
Control power wiring setup To maintain the best possible power supply, install the auxiliary batteries as close as possible to the gate. - Truck installations might not have an auxiliary battery kit (PALFINGER Liftgates always recommends a kit). In this case you have to run the control power straight off the truck battery. -
Page 17: Platform Installation
5 Gate Installation Platform installation To install the platform (if not preinstalled by manufacturer) follow these steps: 1) Unfold platform and clamp on to forklift or overhead crane. 2) Slide out gate to the point that you are able to attach platform clevis to lift arm and tilt cylinders. 3) Bring platform close to gate and attach lift arm to platform using provided pins 4) To attach tilt cylinders hold B-15 platform sensor so that you are able to extend tilt cylinders when turning the tilt switch until you match pinholes on platform and tilt cylinder head... -
Page 18: Lift Arm Up-Stop Installation And Rail Stops Setup
5 Gate Installation Lift arm Up-stop installation and rail stops setup With gate power set up and fully functional, place gate and platform in final operational position for installation of up and slide out stops. Start with up stops and verify flush fit, then continue with slide stops. 3/16“... -
Page 19: Control Box Installation
5 Gate Installation 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 Revision 1.5 - 19 -... -
Page 20: Gate Adjusting And Detailing
6 Gate adjusting and detailing Gate adjusting and detailing Setting B-13 lift arm sensor B-13 Sensor horizontal Lock Tab Tilt Cylinder in this position B-13 Sensor Lift Arm Lift Cylinder 10"-12" Figure 16 B-13 lift arm adjustment • To set the sensor correctly, lift unfolded platform up about 10” to 12” above ground. •... -
Page 21: Setting B-15 Platform Sensor
6 Gate adjusting and detailing Setting B-15 Platform sensor Figure 17 B-15 adjustment on platform • Mount the platform sensor B-15 to the right-hand side of the platform as shown in Figure 18. Make sure to loop wire around to give it enough slack in normal operation and route clear of any pinch points. -
Page 22: Platform Adjusting With Bolts
6 Gate adjusting and detailing Platform adjusting with bolts At the bottom between the main and the tip section are 4 bolts to adjust the platform. These adjusting bolts are horizontal 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. -
Page 23: Electrical Installation
When performing electrical installation, 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. • ANY deviation from PALFINGER Liftgates’ recommended power setup (see 7 Electrical Installation) -
Page 24: Wiring Schematic Main Battery Power - Truck Setup
7 Electrical Installation Wiring schematic main battery power - Truck setup 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 20 Main wiring - truck setup Revision 1.5... -
Page 25: Wiring Schematic Main Battery Power - Trailer Setup
7 Electrical Installation Wiring schematic main battery power - Trailer setup Liftgate Mount Frame Dual pole plug Ground (Third Battery Shown for heavy applications Only) Aux. Batteries Ground Figure 21 Main wiring - trailer setup - dual pole charging system Liftgate Mount Frame Single pole plug Ground... -
Page 26: Trail Charger Installation
7 Electrical Installation Trail charger installation Liftgate Mount Frame 7 way plug – white for tractor power Trail Charger Ground 7 way plug – aux pin for tractor ignition switch Aux. Batteries Ground Ground Figure 23 Trail charger wiring Install the 2 Ga. positive and negative battery cables securely from mount frame to battery and •... -
Page 27: On/Off Switch Installation
7 Electrical Installation On/off switch installation Truck setup 7.5.1 Lead the 4-wire cab switch (J-11 plug) together the 4 wires for the control power (J1 #2 and #27; J2 #“-“) to the batteries along the sub-wood, run the battery cable to the auxiliary batteries (if no aux. kit ordered, run battery cables also to the truck battery). -
Page 28: Control Board Wiring And Connector Setup
7 Electrical Installation Control board wiring and connector setup Verify that this jumper is set; otherwise there will be no flashing light on the platform Figure 26 Control board wiring schematic Revision 1.5 - 28 -... -
Page 29: Control Board Plug Setup
7 Electrical Installation Control board plug setup WARNING FOOT GROUND for PC BOARD B13 LIFT ARM B15 PLATFORM LIGHTS CONTROL (green/yellow and black # 1) CAB ON-OFF CONTROL SWITCH TRUCK ILUK POWER PACK JUMPS to J 11 # 4 POSITIVE for PC BOARD (black #2 to 2 and black # 4 to 27) HAND REMOTE... -
Page 30: Control Box Wiring (Internal)
7 Electrical Installation Control box wiring (internal) 10 wire harness ILU Plus control box setup Control Box Backlight bulb #gn/ye #9 wire is not connected open end on both sides of the wire harness down down #gn/ye TILT SLIDE LIFT Hand Control Figure 28 Control box wiring schematic J-2 #2:... -
Page 31: Hydraulic Schematic
8 Hydraulic schematic Hydraulic schematic 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 S1, S2 on lift cylinder and S7, S8 on push pull valve block are double acting release valves: They have to 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... -
Page 32: Lubrication
8 Hydraulic schematic Lubrication Figure 30 Grease and Lubrication points Location of Grease Zerks (6 on each side, 12 total) Oil level in the power pack tank (see marking inside of power pack reservoir) Platform hinges, Slide Rails and optional Cart Stops (use WD-40 spray for lubrication) •... -
Page 33: Decal Placement
Decal Placement 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. Please make sure to place the maximum capacity decal (D) on driver and curb side. (A) 1 ATG-URGWA - Urgent warning: Elevating gate instructions (B) 1 ATG ILU - Operational Instructions (placed on your Control Box). - Page 34 The picture below will help you to place all decals visible in order to get maximum operational safety. Decal - D Decal - C Decal - A Decal - J Decal - K Decal - F Decal - L Decal - B Decal - G Revision 1.5 - 34 -...
- Page 35 2. Red Grease Caps On Zerks CHECKED BY 3. Bolts Tight On Pins DATE Note: This must be filled out and kept for your records . A copy of this sheet must be presented to PALFINGER Liftgates for warranty reimbursement Revision 1.5 - 35 -...
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