Palfinger ILSL Maintenance And Troubleshooting Manual
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Palfinger ILSL Maintenance And Troubleshooting Manual

Palfinger ILSL Maintenance And Troubleshooting Manual

Sideloader liftgate
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Model ILSL Sideloader Liftgate
Maintenance and Troubleshooting
REV-021920

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Summary of Contents for Palfinger ILSL

  • Page 1 Model ILSL Sideloader Liftgate Maintenance and Troubleshooting REV-021920...
  • Page 2 ALL MODELS OF PALFINGER LIFTGATES Installation, Operator(Owner) and Parts Manuals, are available for download or viewing on our website at https://www.palfinger.com/en-US/usa/products/lift-gates. Diagrams of decal placement are in the Installation and Operator Manuals. Decals are furnished at no cost to our customers.
  • Page 3 Liftgate Components...
  • Page 4 Basic Flooded Battery Conditions and Testing BEFORE YOU START TROUBLESHOOTING 10-10 TEST CHECK BATTERY VOLTAGE Using a multimeter set on DC Voltage: Place Negative lead on Negative Post on Motor. Place Positive lead on Positive Post on Motor. Using the Lift Switch raise the platform to bed level. Keeping the switch activated.
  • Page 5 Make sure King Pin Plate is grounded to side rail. Does Fifth Wheel have a ground strap to the tractor chassis?
  • Page 6 Gate components Lift gate slide rails Trailer Sub frame for mount brackets Push-pull cylinder assembly inside sliding tray Slide in power-pack and control board Lift cylinder – mounted underneath lift arm B-15 Lift Arm Sensor (Easy-move option) Adjustable slide stops Flashing warning lights...
  • Page 7 Circuit Board – Schematic...
  • Page 8 Battery Connections for Trailers Circuit Board & Liftgate Positive and Negative connections...
  • Page 9 Battery Connections for Trucks Circuit Board & Liftgate Positive and Negative connections...
  • Page 10 Circuit Board – September 2013 to Present Not used on ILFP Each Plug on Circuit Board Has a Alphabetical Letter and number on the bottom of plug to represent location On circuit board ( J1 ) In Each Plug on Circuit Board have numbers or Letters Jumper wire Or symbols that represent...
  • Page 11 Circuit Board – September 2013 to Present Not used on ILFP- X Inputs Jumper wire Output...
  • Page 12 Electric controls – connector overview WARNING FOOT LIGHTS CONTROL Platform cable J3 Cab Switch J11 Sensor J41 Valves J4 - 7 Signal f. Lights - 2 Permanent Hot - B15 -> Brown, Blue, Black - 15 Lift cylinder - 5 lift - 4 Control Power - 6 lower - (-) Ground...
  • Page 13 Electric controls – control cable wiring SIGNAL PC-BOARD CABLE # Control box wire setup 12 V HOT GREEN/YELLOW J-30 DOWN GROUND - (-) J-11 MAIN POWER Only if Control box has off & on switch 12 V HOT GREEN/YELLOW SLIDE OUT - 80 J-32 SLIDE IN...
  • Page 14 Electric controls – Truck Cab Switch NOTE: All Models of Palfinger gates supply the power for the cab switch J11 Plug on Circuit Board is connection for Cab Switch, Main Power on terminal # 2 is sent to cab switch and when Switch is turned on Main Power is sent back to Circuit Board to power all # 4 terminals for outputs on Circuit Board.

  • Page 15: Control Box

    Electric controls – control box setup Control Box Backlight bulb #gn/ye #9 wire is not connected #gn/ye Jumper open end on both sides of the wire harness down #gn/ye SLIDE LIFT Hand Control...
  • Page 16 Flush Mount 3 Button Control...
  • Page 17 Wiring schematic – control overview Slide angle sensor Stored position sensor Legend B-15 Lift arm Proximity Switch gn : green bl wt Voltage difference bl : blue between store and br : brown slide position wt : white 0.34 V @ blue ye : yellow sw / bk : black gy : green-yellow...
  • Page 18 Wiring schematic – sliding out activities Stored position sensor Slide angle sensor Proximity Switch B-15 Lift arm bl wt Voltage difference between store and Slide-out signals slide position 0.34 V @ blue Activated pins Activated lines SLIDE IN VALVE SLIDE OUT VALVE On/Off switch CIRCUIT BOARD # 2 BLACK...
  • Page 19 Wiring schematic – lowering Stored position sensor Proximity Switch bl wt Lowering signals Activated pins Activated lines SLIDE IN VALVE SLIDE OUT VALVE On/Off switch CIRCUIT BOARD # 2 BLACK # 4 BLACK # 1 BLACK GREEN / YELLOW 4 WIRE CABLE 2 GA CABLE...
  • Page 20 Wiring schematic – lifting activities Stored position sensor Proximity Switch bl wt Lifting signals Activated pins Activated lines SLIDE IN VALVE SLIDE OUT VALVE On/Off switch CIRCUIT BOARD # 2 BLACK # 4 BLACK # 1 BLACK GREEN / YELLOW 4 WIRE CABLE 2 GA CABLE...
  • Page 21 Wiring schematic – sliding in activities Stored position sensor Proximity Switch bl wt Slide-in signals Activated pins Activated lines SLIDE IN VALVE SLIDE OUT VALVE On/Off switch CIRCUIT BOARD # 2 BLACK # 4 BLACK # 1 BLACK GREEN / YELLOW 4 WIRE CABLE 2 GA CABLE...
  • Page 22 Pins, Bushings and Restrictor Valves Restrictor Valve Number on valve describes the fluid flow (liters per minute) Pin diameter determines lifting capacity...
  • Page 23 Power-pack and components S5 shift valve Ground post Positive post A & B port for hydraulic hoses Pressure gauge connector Motor solenoid with positive post from battery...

  • Page 24: Side View

    Power-pack and components S5 Shift valve Motor Studs Oil filler cap Side view Motor Solenoid Suction filter in oil tank CHECKING FLUID LEVEL Liftgate retracted underneath Hydraulic trailer, lowered to the ground. connections to cylinders Fill to approximately 1” from top of reservoir.

  • Page 25: Lift Cylinder

    Lift and Push-Pull cylinders Restrictor Solenoid Valve Hose Connection “A” Lift Cylinder Hose Hose Connection Connection “A” “B” Push-Pull Cylinder...
  • Page 26 Lift and Push-Pull cylinder connection Push-pull cylinder...
  • Page 27 Valve Block connections S-7 and S-8 Valves To Plug J-42 with Ground Wires...
  • Page 28 Hydraulic symbols in schematics Motor with Pump Shift valve S5 Pressure relief valve Pressure gauge Single locking valve Shuttle valve / (Flow divider) Restrictor valve Double locking valve...
  • Page 29 Hydraulics Push-pull cylinder Hydraulic components of the Underslider unit: • Powerpack with pump & motor and shift valve S5 • Distribution block on back of main tube with lock valve and Distribution block Slide valves S7 & S8 • Push-pull cylinder assembly centered in tray on main frame •...
  • Page 30 Hydraulic action – sliding out Motor starts running and S8 valve is energized. • Oil pressure on input “A” sets exits “Av” and Bv” at the valve block under pressure. • The surface at the piston rod on input “B” is lager than on the shaft at input “A”...
  • Page 31 Hydraulic action – lowering The shift valve S5 at the pump and the solenoid release valves S1 and S2 at the cylinders will get energized. In addition the leaking down stop valve S11 in the back of the mount frame is also energized.
  • Page 32 Action – auto tilt down The automatic tilt function is based on a mechanical swing fixture which is swinging away from the main tube to tilt the platform down. This allows the gate to always sit flat on the ground for an easy loading and unloading.
  • Page 33 Hydraulic action – lifting Motor starts running and double locking release valves S1 and S2 are energized. •The pressure is on input “A” at the valve block. The oil passes the S11 valve and sets pressure on exit “AH”. • The energized double locking...
  • Page 34 Hydraulic action – sliding in Motor starts running and S7 valve is energized. • Oil pressure on input “A” sets pressure on exits “Av” at the valve block. • The Oil pressure on exit “Av” at the valve block sets pressure on input “A”...
  • Page 35 K plus Circuit Board 2005 to August 2013 – board connectors by row Row 2 Row 1 J-3 foot controls & w/lights J-11 cab on/off switch Push-pull Foot control Main Ground Jumper controls J-42.1 Push-Pull valves K plus Circuit Board 2005 to August 2013 J-1 main battery power motor solenoid &...
  • Page 36 ILFP Electrical Control Overview of Circuit Board, Connectors and Electrical Schematic K plus Circuit Board M Control Circuit Board 2005 to August 2013 August 2013 and newer M Control Circuit Board with L.E.D. Digital Fault Code Display...
  • Page 37 New Style Circuit Board – M Control Protective Cover LED flashes green when OK Slots sized for specific plugs LED flashes red when a fault exists Prevent plugs from being LED in lower left corner shows plugged in wrong code for fault...
  • Page 38 Check Circuit Board for Showing defective / missing B-15 B-15 not on the ILFP & ILSL correct Program Check J-1 & J-2 power cable at PC board and Short on platform warning lights Power consumption J3 pin 7 to high...
  • Page 39 Clear Fault Code on MBB Control Circuit Board Remove J-11 Plug from Circuit Board for Plug in J-11 on Circuit Board. 10 seconds to clear fault code. Digital display should read 0 or 1. If fault code is still displayed after plugging in the J-11 plug, a fault still exists in the system.
  • Page 40 Power Cable to Solenoid Coil Test 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 41 Solenoid Coil Test If one or both release valves on lift cylinders are not opening up, low voltage may be the cause. A minimum of 9V is necessary to properly energize each of the solenoid coils. If the minimum voltage is present at both coils, the coil may not be generating the magnetism needed to open the solenoid valve.

  • Page 42: Preventive Maintenance

    Preventive maintenance - Lubrication: 16 grease points (8 grease points each side; 4 at mount frame, 4 at platform) - Hydraulic oil: filler cab on top of reservoir, outlet at bottom of tray underneath alum block - Hydraulic System: Check for hydraulic leaks at hose fittings and cylinders shafts - Power Supply: Check battery power supply (above 10V) at J11 #4 and JK(-) at deadhead* - Pins:...

  • Page 44: Maintenance And Care

    Maintenance and Care...

  • Page 45: Maintenance Checklist

    6. Check for oil leakage around the power pack and Use only original spare parts. If in doubt contact your inside mount tube. Tighten or replace components if PALFINGER Liftgates distributor or call PALFINGER needed. If you perform work on any hydraulic Liftgates directly.
  • Page 46 Troubleshooting By Function 1. Before starting any Troubleshooting always confirm battery voltage is above 12.5 Volts. 2. All batteries have been load tested and connection are clean and connected correctly. 3. Next quick check is perform 10 -10 test refer to page 4 in this manual. 4.
  • Page 47 Troubleshooting By Function 1.2 Liftgate is not lowering but lifting and sliding 1.3 Check for Short in optional equipment 1.3 Check for Short in optional equipment...
  • Page 48 Troubleshooting By Function 1.4 Check voltage supply to release valves on lift cylinders 1.5 Gate is lowering down very slowly, S5 at pump not engaged...
  • Page 49 Troubleshooting By Function 2. Liftgate dose not slide out 2.1 Check Battery Power 2.2 Check for Short in optional equipment...
  • Page 50 Troubleshooting By Function 2.3 Check voltage supply to release valve for push-pull cylinder 2.4 Check motor solenoid power...
  • Page 51 Troubleshooting By Function 3. Liftgate is not lifting up 3.1 Check Battery Power 3.2 Check function of control box 3.3 Check for short in optional equipment...
  • Page 52 Troubleshooting By Function 3.4 Check motor solenoid power to run the motor 3.5 Check voltage supply to release valves on lift cylinder...
  • Page 53 Troubleshooting By Function 4. GATE IS NOT SLIDE IN 4.1 Check Battery Power 4.2 Check for short in optional equipment 4.3 Check function of control box...
  • Page 54 Troubleshooting By Function 4.4 Check motor solenoid power to run the motor...
  • Page 55 5:00pm ET, Monday thru Friday Jorge Gallardo – Asst. Tech Support and Warranty Kim Loran- Parts Asst, Manager 609-587-4200 ext. 127 562-252-0407 K.loran@palfinger.com j.gallardo@palfinger.com Ben Styer – Parts Asst. / Technical Support Rey Rodriguez – Parts Asst. 609-587-4200 ext. 126 562-252-0410 b.styer@palfinger.com...

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