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Palfinger ILFP Maintenance And Troubleshooting Manual
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Palfinger ILFP Maintenance And Troubleshooting Manual

Palfinger ILFP Maintenance And Troubleshooting Manual

Underslider liftgate
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Model ILFP Underslider Liftgate
Maintenance and Troubleshooting
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Summary of Contents for Palfinger ILFP

  • Page 1 Model ILFP Underslider Liftgate Maintenance and Troubleshooting...
  • Page 2 ALL MODELS OF PALFINGER LIFTGATES Installation, Operator(Owner) and Parts Manuals,troubleshooting guides, hydraulic and electrical schematics 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 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 4 FLOODED LEAD ACID BATTERY INFORMATION • A flooded lead acid battery reading 12.0V is at less than half charged • Flooded lead acid batteries work best at 90 degrees F. Performance is reduced as temperatures increase or decrease above or below 90 degrees F •...
  • 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 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 7: Side View

    Power-pack and components S5 Shift valve Motor Studs Oil filler cap Motor Solenoid Suction filter in oil tank Side view Hydraulic connections to cylinders Pressure Gage plug Tray lock bold Below valve block: Oil drainage screw 6mm hexagon socket Positive Stud Ground Pressure adjustment valve Stud...

  • Page 8: 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 9 Lift and Push-Pull cylinder connection Push-pull cylinder...
  • Page 10 Valve Block connections S-7 and S-8 Valves To Plug J-42 with Ground Wires...
  • Page 11 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 12 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 13 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 14 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 15 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 16 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 17 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 18 Electric controls – 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 J-1 main battery power motor solenoid & shift valve at block J-30 main control cox J-4 lift cylinder valves J-32 Push-Pull control signals...
  • Page 19 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 20 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 SLIDE OUT - 80 J-32 SLIDE IN - 81 Hand control wire setup -5.2 # YELLOW J-31 DOWN...
  • Page 22 Electric controls – Liftgate with no Circuit Board...
  • Page 23 Electric controls – Liftgate with no Circuit Board...
  • Page 24 Electric controls – Liftgate with no Circuit Board...
  • Page 25 Electric controls – Liftgate with no Circuit Board...
  • Page 26 Electric controls – board overview FOOT Easy CONTROL GROUND for PC BOARD move option Inputs Output Sensors JUMPER SLIDE VALVES POWER PACK CONTROL PANEL Easy move Proximity Switch CYLINDERS POSITIVE for PC BOARD LIFT 15 (2 ea) PUSH-PULL (black #2 to 2 CYLINDERS and black # 4 to 27) SECONDARY HARNESS...
  • Page 27 Electric controls – slider specialties FOOT CONTROL GROUND for PC BOARD Connector for P/P valves JUMPER SLIDE VALVES Warning light POWER PACK control jumper CONTROL PANEL Easy move (with no easy move) Proximity Switch Connector for P/P switch signals CYLINDERS (2 extra wires out POSITIVE for PC BOARD LIFT 15 (2 ea)
  • Page 28 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 29 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 30 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 31 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 32 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 33 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 34 Lift gate operating diagnostics – Input signals How to check input signals on circuit board (J-3;J-30;J-31;J-32): Main power = terminals #2 & #27 Switched 12 V power = terminals #4 Slide out signal = terminal #81 Slide in signal = terminal #80 WARNING FOOT LIGHTS...
  • Page 35 Lift gate operating diagnostics – Output signals How to check output signals on circuit board (J-4;J-1;J-41;J-42) Slide-out gate: Motor solenoid = terminal J1 - #3 Motor is running Release valves S8 P-P cylinder = terminal J42 - #81 Valves open to release fluid out of cylinder Warning lights start flashing Lower gate: Shift valve S5 &...

  • Page 36: On-Site Troubleshooting

    On-site troubleshooting 1) Check 150 Amp circuit breaker and 20 Amp fuse at batteries and fuses on J1 plug at PC board 2) Unplug not necessary equipment to eliminate possible problems  J-31 - hand control  J-3 - warning light & foot controls ...
  • Page 37 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 38 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 39 Circuit Board – M Control Fault Codes Digital Fault Code Display located in lower left corner of M Control Circuit Board...
  • Page 40 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 41 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 42 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 43: Preventive Maintenance

    Preventive maintenance - Lubrication: 12 grease points (6 grease points each side; 3 at mount frame, 3 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 Joe Tabella – Technical Support/Branch Manager, NJ WEST COAST - Cerritos, CA - 8:00am to 5:00pm PT, Monday thru Friday 609-587-4200 Jorge Gallardo – Asst. Tech Support j.tabella@palfinger.com Ben Styer – Technical Support and Warranty Manager 888-774-5844 ext 19 608-587-4200 ext 126 j.gallardo@palfinger.com...