Palfinger LIFTGATES ILM plus Series Troubleshooting Manual
Palfinger LIFTGATES ILM plus Series Troubleshooting Manual

Palfinger LIFTGATES ILM plus Series Troubleshooting Manual

Ilm medium duty railgate lift

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Troubleshooting: ILM Medium Duty Railgate Lift
Table of content:
Gate overview ............................................................2
1)
Pump and Motor Setup overview ....................................3
2)
Controller Identification Overview ...................................4
3)
Chain routing ( Standard ILM+ ) ....................................5
4)
Chain routing ( Above floor ILM+ ) ..................................6
5)
Gate does not opening up..............................................7
6)
Gate is not lowering down ............................................8
7)
Gate is not raising up......................................................9
8)
Gate is not closing .....................................................10
9)
Electrical Diagram Manual Closing .................................11
10)
Hydraulic Schematic Manual Closing .............................12
11)
Hydraulic Schematic MC Lift Function .......................... 13
12)
Hydraulic Schematic MC Lower Function ........................ 14
13)
Electrical Diagram Power Closing...................................15
14)
Hydraulic Schematic Power Close ................................16
15)
Hydraulic Schematic PC Lift Function ........................... 17
16)
Hydraulic Schematic PC Open Function ....................... 18
17)
Hydraulic Schematic PC Lower Function ...................... 19
18)
Hydraulic Schematic PC Close Function ...................... .20
19)
Platform not lowing down Test .................................... 21
20)
Check ground on solenoid valves................................ 22
21)
Testing solenoid valves and cables ............................. 23
22)
Pump pressure adjustment ........................................24
23)
24)
25)
Tools needed:
1.) Voltmeter
2.) Test light
3.) 8" jumper cable (16ga. or smaller)
4.) Philips Screw driver
5.) 13mm (1/2") wrench
*****MAKE SURE YOUR BATTERIES ARE FULLY CHARGED AND IN GOOD CONDITION*****
Always use CAUTION and allow SAFE distance from moving parts
Practice SAFETY, using common sense and good judgment
- Series
ILM
plus
Page
Rev-07272022 P1

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Summary of Contents for Palfinger LIFTGATES ILM plus Series

  • Page 1: Table Of Contents

    Check ground on solenoid valves………………………….. 22 Testing solenoid valves and cables ……………………….. 23 Pump pressure adjustment ………………………………….24 Gate chattering or sticking in rails Inspection Steps.25,26,27,28. Palfinger Technical Support & Parts Contact list ………… 29 Tools needed: 1.) Voltmeter 2.) Test light 3.) 8”...
  • Page 2: Gate Overview

    plus Series Gate overview Rail Serial # tag Platform Rail Storage Latch 15.1 15.2 Runners Platform Storage 15.3 15.4 Safety Latch Storage Latch 15.5 Side 15.6 Chain Operating Controls Lift Cylinder 16.1 (Inside) 16.2 Open/Close Restrictor location Hydraulic 16.3 16.4 Power Unit (Inside) Power...
  • Page 3: Pump And Motor Setup Overview

    plus Pump and Motor Setup Overview Series Hydraulic Lift Cylinder Pressure Filler Vent Cap Hose Adjustment Oil Filler 1" Hydraulic Power Unit Reservoir Motor Reservoir Motor Solenoid S1 Lift/Lower S2 Open/Close Valve Valve Hydraulic Fluid Installed From Factory Alternative Fluids Property HYDREX MV ARCTIC 15 Temperature Range...
  • Page 4: Controller Identification Overview

    Controller Identification & Operation Overview plus Series Power Open and Close will have three button controller 70-0709-901 Main Liftgate 3-Button Control 2025982 Cab Switch Harness Diode Inside Remote Schematic Power Red Wire 12 Volt Power Load Ground Motor Solenoid Green Wire Cab Cut-Off Switch 70-1012-002 S2 Open/Close Valve...
  • Page 5: Chain Routing ( Standard Ilm+ )

    plus Chain Routing – Standard ILM+ Series...
  • Page 6: Chain Routing ( Above Floor Ilm+ )

    plus Chain Routing – Above Floor ILM+ Series...
  • Page 7: Gate Does Not Opening Up

    plus Series 1) GATE DOES NOT OPEN UP 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 →...
  • Page 8: Gate Is Not Lowering Down

    plus Series 2) GATE IS NOT LOWERING DOWN 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 →...
  • Page 9: Gate Is Not Raising Up

    plus Series 3) GATE IS NOT RAISING UP 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 →...
  • Page 10: Gate Is Not Closing

    plus Series 4) GATE IS NOT CLOSING a) Initial Checks → Check Cab Switch is "ON“( Optional ) → Check that Circuit Breaker at battery box 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.
  • Page 11: Electrical Diagram Manual Closing

    plus Series Wiring Diagram (Manual Closing)
  • Page 12: Hydraulic Schematic Manual Closing

    Hydraulic Schematic (Manual Closing) plus Series Cylinder Valve Body Lift Cylinder Cap Port Port Pump Unit Port Flow Control Press-Comp 1.0 gpm Shuttle Valve Motor Motor Pump Relief Valve 2900 psi Filter Reservoir Tank ILM Wiring Schematic - Manual Closing 15939 Piuma Ave.
  • Page 13: Hydraulic Schematic Mc Lift Function

    Hydraulic Schematic (Manual Closing) plus Lift Function Series Green = 12 Volt Power Active = High Pressure Blue = Low Pressure Cylinder Valve Body Lift Cylinder Cap Port Port Pump Unit Port Flow Control Press-Comp 1.0 gpm Shuttle Valve Pump Relief Valve 2900 psi Lift Function...
  • Page 14: Hydraulic Schematic Mc Lower Function

    Hydraulic Schematic (Manual Closing) plus Lower Function Series Green = 12 Volt Power Active = High Pressure Blue = Low Pressure Cylinder Valve Body Lift Cylinder Cap Port Port Pump Unit Port Flow Control Press-Comp 1.0 gpm Shuttle Valve Lowering Function Motor Pump Relief Valve...
  • Page 15: Electrical Diagram Power Closing

    plus Wiring Diagram (Power Closing ) Series...
  • Page 16: Hydraulic Schematic Power Close

    Hydraulic Schematic (Power Closing) plus Series Cylinder Valve Body Lift Cylinder Port Flow Control Fixed #035 Port Pump Unit Port Flow Control Press-Comp 1.0 gpm Shuttle Valve Motor Pump Relief Valve 2900 psi Filter Reservoir Tank ILM Wiring Schematic - Power Closing 15939 Piuma Ave.
  • Page 17: Hydraulic Schematic Pc Lift Function

    Hydraulic Schematic (Power Closing) plus Lower Function Series Green = 12 Volt Selected = High Pressure Blue = Low Pressure Cylinder Valve Body Lift Cylinder Port Flow Control Fixed #035 Port Pump Unit Port Flow Control Press-Comp 1.0 gpm Shuttle Valve Lowering Function S1 Valve Motor...
  • Page 18: Hydraulic Schematic Pc Open Function

    Hydraulic Schematic (Power Closing) plus Open Function Series Green = 12 Volt Selected = High Pressure Blue = Low Pressure Cylinder Valve Body Lift Cylinder Port Flow Control Fixed #035 Port Pump Unit Port Flow Control Press-Comp 1.0 gpm Shuttle Valve Open Function S2 Valve Motor...
  • Page 19: Hydraulic Schematic Pc Lower Function

    Hydraulic Schematic (Power Closing) plus Lift Function Series Green = 12 Volt Selected = High Pressure Blue = Low Pressure Cylinder Valve Body Lift Cylinder Port Flow Control Fixed #035 Port Pump Unit Port Flow Control Press-Comp 1.0 gpm Shuttle Valve Lift Function Motor &...
  • Page 20: Hydraulic Schematic Pc Close Function

    Hydraulic Schematic (Power Closing) plus Close Function Series Green = 12 Volt Selected = High Pressure Blue = Low Pressure Cylinder Valve Body Lift Cylinder Port Flow Control Fixed #035 Port Pump Unit Port Flow Control Press-Comp 1.0 gpm Shuttle Valve Close Function Motor &...
  • Page 21: Platform Not Lowing Down Test

    plus Platform is not lowering down Series Remove hydraulic line from pump and motor and remove vent cap and put the hydraulic line in the tank vent hole and push the down button on controller, if gate goes down problem 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...
  • Page 22: Check Ground On Solenoid Valves

    plus Check grounds on valves Series Check 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: Testing Solenoid Valves And Cables

    plus Power Cable to Solenoid Coil Test Series Check for broken power wire in solenoid cable: • Unplug connector at valve. • Set multimeter to read DC voltage. • Put positive lead of multimeter in plug. • Put negative lead of multimeter in other hole of plug.
  • Page 24: Pump Pressure Adjustment

    The pressure on the pump is set at the factory and normally no adjustment is needed. If you feel adjustment is necessary please contact Palfinger Field Technical support person in your area which will be listed on last page of this document before proceeding with adjustment.
  • Page 25 plus Gate chattering or sticking in columns Series Inspection Steps Step 1. Check rails are square and parallel in X,Y, and Z axis. Welded to truck correctly. (see Installation Manual page 19). Step 2. Check Rails for items listed below •...
  • Page 26 Lift gate chattering or sticking in columns plus Inspection Steps Series Step 3. Check Chains and Sprockets • Roller chains are adjusted so deck is 1/8” above floor , left and right sides. • Roller chains have even tension left and right while cycling unit, jam nuts are tight on adjusting anchors.
  • Page 27 VOID your WARRANTY on the slide bearings. Column Lubrication: The columns are designed to run DRY and this is what Palfinger recommends first. However, in some wet or dirty environments, the columns may require periotic lubrication. The schedule will vary based on cycles, load, and environment.
  • Page 28 plus Series Oil: - Columns Hydraulic Oil: - Resevoir 1 Zerks: - 1 Platform 2 Zerks: - 1 Platform - 1 Cylinder - Grease fitting, 2 for deck, 2 for power closing. 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.) - Deck support chains and optional Cart Stops (use light penetrating oil) -Columns (optional) use 0W20 motor oil .
  • Page 29: Gate Chattering Or Sticking In Rails Inspection Steps.25,26,27,28. Palfinger Technical Support & Parts Contact List

    Monday thru Friday Jorge Gallardo – Asst. Tech Support and Warranty Ben Styer – Parts Asst. / Technical Support Manager 609-587-4200 ext. 126 562-252-0407 b.styer@palfinger.com James Ross – Parts Asst. j.gallardo@palfinger.com Rey Rodriguez – Parts Asst. 609-587-4200 ext. 129 562-252-0410 j.ross@palfinger.com...

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