Palfinger ILF 33 Installation Manual & Check-Off Sheet Download Page 6

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ILF 33/44/55 Installation Manual

Rev 1.1

Safety Information

This manual follows the g

uidelines set forth in “ANSI Z535.4-2007” for alerting you to possible

hazards and their potential severity.

This is the safety alert symbol. It is used to alert you to potential personal injury hazards.

Obey all safety messages that follow this symbol to avoid possible injury or death.

! DANGER

indicates an imminently hazardous situation which, if not avoided, will result in death or

serious injury.

! WARNING

indicates potentially hazardous situation which, if not avoided, could result in death or

serious injury.

! CAUTION

indicates a potentially hazardous situation which, if not avoided, may result minor or

moderate injury.

CAUTION

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 potentially hazardous situation which, if not avoided,

may result in property damage.)

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.)

Summary of Contents for ILF 33

Page 1: ...ILF 33 3300 lbs Capacity ILF 44 4400 lbs Capacity ILF 55 5500 lbs Capacity INSTALLATION MANUAL CHECK OFF SHEET 09 16 ...

Page 2: ...to change without notice Visit www palfinger com for up to date information and notifications If you received this product with damaged or missing parts contact Palfinger Liftgates at 888 774 5844 Parts Order liftgateparts palfinger com Technical Support technicalapplications palfinger com PALFINGER Liftgates LLC 15939 Piuma Ave Cerritos CA 90703 Tel 888 774 5844 Fax 562 924 8318 PALFINGER Liftgat...

Page 3: ... 6 4 Bed Extension Installation 20 6 5 Dock Bumper Installation Weld On Optional 22 6 6 7 Liftgate Installation Truck 24 Installation 24 7 1 8 Liftgate Installation Trailer 30 Installation 30 8 1 Operation of B 15 Sensor 34 8 2 Operation of B 13 Sensor 35 8 3 9 Electrical Installation 36 Wire Crimping 37 9 1 Circuit Breaker Installation 38 9 2 Cable Routing 39 9 3 Main Power Connections 40 9 4 On ...

Page 4: ...ydraulic Schematic 51 12 Decal Placement and Inspection 52 13 Final Inspection Check List 54 Company Information Company Name Advisor Name Trailer Year Make Model Liftgate Information Liftgate Serial Number Liftgate Model Number Date of Purchase Date of Installation ...

Page 5: ...ILF 33 44 55 Installation Manual Rev 1 1 5 1 Manual Updates for v1 1 Updated Section 7 8 Foot control installation Updated Section 8 2 Decal placement ...

Page 6: ...lt in death or serious injury WARNING indicates potentially hazardous situation which if not avoided could result in death or serious injury CAUTION indicates a potentially hazardous situation which if not avoided may result minor or moderate injury CAUTION 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 potential...

Page 7: ...e starting your Installation Refer to your truck manufacturer s instructions before adding any auxiliary equipment Installer is responsible for compliance with this manual OEM and FMVSS requirements All welding should be performed by qualified personnel per AWS standards Always Ground closest to your welding point to prevent arcing through moving parts or electrical parts Contact PALFINGER Liftgat...

Page 8: ...ed by a Palfinger Liftgates Authorized Service Center This manual has been designed for use in conjunction with the ILF series liftgates only which is designed for different capacities There are four options to determine the model and serial number of the installed liftgate 1 Refer to the serial number tag on the liftgate Top of Mount Frame 2 Ask your employer or lessor 3 Call your PALFINGER Liftg...

Page 9: ...her such support structures may VOID your trailer warranty Call technical support before starting the installation if any questions or concerns arise on mounting dimensions or procedures Mounting Notes Read and clearly understand manual BEFORE beginning ANY work The basic rule of PALFINGER Liftgates s ILF installation is to lift mount frame to achieve MAXIMUM ground clearance WITHOUT exceeding Min...

Page 10: ...ILF 33 44 55 Installation Manual Rev 1 1 10 4 Dimension Sheet ...

Page 11: ...ILF 33 44 55 Installation Manual Rev 1 1 11 ...

Page 12: ...Bumper Bed Extension Mount Frame Tilt Arm Lift Arm Control Box Hydraulic Power Unit Aluminum Platform Mount Plates Parting Wheel ILF 33 Bumper Bed Extension Mount Frame Tilt Arm Lift Arm Control Box Hydraulic Power Unit Steel Aluminum Platform Mount Plates Parting Wheels ILF 44 55 ...

Page 13: ...ø1 2 x 3 L 1 pc Copper Bus Bar 1 pc Circuit Breaker 1 pc Owner s Manual 1 pc Installation Manual 1 pc Battery Lug 5 16 1 pc Decal Kit 15 pcs 8 Nylon Cable Tie 12 pcs Ring Connector 3 8 1 pc Butt Splice 1 pcs Holster 1 pc 3 Button Hand Control 1 pc Cable Clamp 5 pcs Screws 2 pcs Mount Plate Gusset Only for ILF 55 2 pcs Z Brackets 2 pcs ...

Page 14: ...ound clearance Don t exceed max ground clearance Minimum bed height is when truck trailer is loaded to MAX GVW K Mount Clearance Reference F Dim Bed Height Max 62 Min 46 G Ground Clearance Sill ILF 33 Mounting Dimension Table Bed Height Loaded F Dim G Dim K Dim Ref 62 33 20 29 58 32 19 30 56 31 18 31 54 30 17 31 5 52 29 16 32 5 50 28 15 33 48 27 14 34 46 26 13 35 ...

Page 15: ...3 21 12 17 13 Assuming 26 F Dimension Assuming 27 F Dimension Assuming 28 F Dimension Cut Assuming 29 F Dimension Assuming 30 F Dimension Assuming 31 F Dimension Assuming 32 F Dimension Assuming 33 F Dimension Cut Cut Cut 2 If the vehicles sill measures more than 4 in height add a spacer to the rear of the vehicle Fig 2 The spacer will shift the bed extension back allowing the platform to clear th...

Page 16: ...ble for best ground clearance Don t exceed max ground clearance Minimum bed height is when truck trailer is loaded to MAX GVW K Mount Clearance Reference F Dim Bed Height Max 55 Min 50 G Ground Clearance Sill ILF 44 55 Mounting Dimension Table Bed Height Loaded F Dim G Dim K Dim Ref 55 28 19 5 26 54 53 27 19 27 52 51 26 18 28 50 25 17 29 ...

Page 17: ... 13 21 12 17 13 Assuming 26 F Dimension Assuming 27 F Dimension Assuming 28 F Dimension Cut Assuming 29 F Dimension Assuming 30 F Dimension Assuming 31 F Dimension Assuming 32 F Dimension Assuming 33 F Dimension Cut Cut Cut 4 If the vehicles sill measures more than 4 in height add a spacer to the rear of the vehicle Fig 4 The spacer will shift the bed extension back allowing the platform to clear ...

Page 18: ...5 NOTE Palfinger Liftgates does not supply cap materials All material must be supplied by end user 1 Suggested components 2 x3 x3 16 angle and flat bar stock Cut material to size Chassis Wooden Spacer 1 4 Thk Flat Bar 2 x3 x3 16 Angle Chassis Wooden Spacer 1 4 Thk Flat Bar 2 x3 x3 16 Angle Sill Vehicle Frame Cutout Rear of Vehicle Body Long Rail Frame Cap Fig 5 ...

Page 19: ...ILF 33 44 55 Installation Manual Rev 1 1 19 NOTES ...

Page 20: ...per weights and clamps to maintain channels in a flush position Keep the channels in place as they will serve to level the platform during installation Fig 7 2 Verify bed extension is centered on body and flush with channel 3 Weld 3 16 x 4 welds on approximately 10 centers and alternate welds on top and bottom of bed extension Do not weld across the corner posts Fig 8 Bed Extension Sill Weight 300...

Page 21: ... 44 55 Installation Manual Rev 1 1 21 Do Not Weld Area 3 16 Bottom of Bed Extension Welding Area Do Not Weld Area 4 10 3 16 4 10 Top of Bed Extension Welding Area Weld On Bed Extension Welding Locations Fig 8 ...

Page 22: ... 2 pcs Steps 1 Dock Bumper Position the dock bumper against the bed extension make sure everything is squared vertically and horizontally Clamp dock bumpers onto the bed extension Remove the plastic cap from the top of the extension channel prior to welding Tack weld the bumper to the bed extension Fig 9 Bed Extension Vehicle Body 3 16 90 Dock Bumper Rubber Bumper Extension Channel Plastic Cap Fig...

Page 23: ...nimum of three of the vehicles cross members move the channel horizontally for adjust if necessary Fig 10 Use clamps or similar devices to hold the support channels in place Next position the strut against the dock bumper and support channel clamp in place Finally weld all components 100 as shown Dock Bumper Extension Step Optional Accessory 3 16 3 16 Dock Bumper Strut Support Channel Bed Extensio...

Page 24: ...on process for an ILF 33 ILF 44 and ILF 55 is the same for all gates For illustration purposes an ILF 44 is shown Protect all wires and cable from dropping slag or splatter when welding mount plates Make sure to have power pack pulled out when welding the tube and hoses and cables are away from walls Do no apply a load to the platform at anytime during installation Installation 7 1 1 Hoist Platfor...

Page 25: ...Dimension F Dimension should be determined from Section 6 of this manual Use floor jack or equivalent to position the frame assembly up to the required F dimension Fig 13 Use a second jack to level out the under ride guard if necessary Check for squareness vertically and horizontally 12V power supply may be required to release pressure on lift cylinder valves if power is required continue to the E...

Page 26: ...contact with the inside walls of the tube prior to welding Cover Mount Tube Hardware Pull Out 5 Weld the mount plates to the liftgates mount tube Remember to keep the mount tube centered to the truck Determine the overall width of the frame and position the mount plates at the same distance Weld all around the mount plates and tube on both sides of the mount plates Fig 15 NOTE ILF 55 will have an ...

Page 27: ...mount plates and truck frame Clamp mount plates to the chassis frame to prevent any misalignment before welding Tack weld mount plates to vehicle frame Recommendation Add a support plate to the top of the mount plates if needed to tie liftgate mount plates to the body stringer Fig 17 NOTE When the mount plate is welded on the chassis frame the ground electrical from the chassis is transferred to t...

Page 28: ...FORM 8 After completion of the electrical installation Raise platform to be flush with the 3 channels If the platform is not flush the mount tube will need to be adjusted remove tack welds and make adjustments to get the platform to be flush If the platform is leveled with the 3 channels proceed with completing the installation 3 channels Supported Mount Frame Be extremely cautious when testing Re...

Page 29: ...ly Weld 100 with welds against the frame and both sides of the plates against the mount frame Before running the unit through its cycle make sure that the In Cab Switch is in the ON position Lights are on Before running the unit through its cycle make sure that the solenoids on the lift cylinders are not hitting the mount plates ...

Page 30: ...r to beginning installation assure the vehicle is on a leveled surface Installation 8 1 1 Install the sub frame channels onto the trailer chassis Weld the sub frame channels onto as many cross members as possible Fig 18 The inside distance of the channels will determine what distance the mount plates will be installed Trailer Frame w Sub Frame Channels Dimension determines the distance of the moun...

Page 31: ...d horizontally to the trailer Use a minimum of 8 overlap between the mount plates and sub frame channel Clamp mount plates to sub frame to prevent any misalignment before welding 90 F Dimension Support Jacks 3 channels Sub Frame Channel Sub Frame Channel Rear View of Trailer Recommended Support Plates along sub frame channel for strength Not supplied by Palfinger Mount Plate Sub Frame Channel Stre...

Page 32: ...the electrical installation Raise platform to be flush with the 3 channels If the platform is not flush the mount tube will need to be adjusted remove tack welds and make adjustments to get the platform to be flush If the platform is leveled with the 3 channels proceed with completing the installation 3 channels Supported Mount Frame Be extremely cautious when testing Remember that the Liftgate is...

Page 33: ...ly Weld 100 with welds against the frame and both sides of the plates against the mount frame Before running the unit through its cycle make sure that the In Cab Switch is in the ON position Lights are on Before running the unit through its cycle make sure that the solenoids on the lift cylinders are not hitting the mount plates ...

Page 34: ...the platform to tilt down as close as possible to the ground for easy loading and unloading of cargo To adjust the B 15 sensor if necessary 1 Loosen 2 5mmx50mm Allen Head sensor mount screws and rotate slightly for re adjustment Fasten screws after adjustment is complete TIRE Cable Cover Clamp B 15 Sensor Liftarm Platform Profile Warning Light Foot Control option Harness Bottom View of Platform Wa...

Page 35: ...round several times to verify proper operation Tilt sensor slightly forward or back to achieve proper Auto Tilt action Lift Arm Curb Side B 13 Sensor Lock Tab Resin B 13 Sensor 12 15 90 Under torqued B 13 lock bolt may allow sensor to shift during normal gate operation At NO time should the platform tilt tip towards ground while lowering Platform should ONLY tilt AFTER Lift Arms Nylon Rollers cont...

Page 36: ...ircuit breaker at the batteries unless otherwise instructed by the PALFINGER Liftgates technical support team All connections should be heat shirk protected and all open ended terminals must be replaced with closed end terminals or the open ends must be protected with heat shrink tubing Never secure a cable in a way where it can make contact with other wiring brake fuel or air lines or get pinched...

Page 37: ...e to be crimped Straighten out the exposed copper wire and insert into the battery terminal Slide the provided heat shrink over the battery cable 2 Use a crimping tool designed for crimping battery terminals for best results The use of other tools to crimp terminals could possibly damage the battery terminal and make poor connections between the wire and terminals 3 Slide the provided heat shrink ...

Page 38: ...uge jumper from BAT stud on breaker to positive battery post if circuit breaker is not mounted on battery When circuit breaker is mounted on battery use the provided buss bar on the BAT stud Fig 22 Note 150 amp minimum circuit breaker required Circuit Breaker Location Circuit Breaker Location Battery Box Buss Bar Jumper Battery Mount Battery Box Mount Buss Bar To Positive Battery Terminal 2 Gauge ...

Page 39: ... clamps or staples against the wooded spacer s 3 The use of wire loom is highly recommended to protect and facilitate cable routing Wire loom not supplied Body Long Sill Wooden Spacer s Chassis Frame U Bolt Cable Routed Outside of U Bolts Insulated Cable Clamps Inspect and test all electrical connections wiring and the different functions to make sure that the electrical installation is complete ...

Page 40: ...onductor Control Power Cable from Control Board Wires 1 and Gr Yl go to ground Control Board Location Inside Ground Battery Wiring Setup Truck Battery Wiring Setup Trailer In Line ATC Fuse 20 Amp Replace with same amperage fuse when necessary Resettable Circuit Breaker 150 Amp Min Replace with same amperage breaker when necessary Ground For optimal grounding ground all batteries and power units to...

Page 41: ... seen and reached from the driver s seat as well as from the ground Fig 23 No Use Blue 4 Black Black Yellow Green Yellow Green 2 4 1 Red 2 J11 Black Blue 3 White 1 J11 From Control Board In Cab ON OFF Switch Wiring Table Cable Number Marking Color Function 1 White Hot lead to red LED lights Yellow Green Ground to LED lights 2 Red 12V Power from batteries 4 Blue Control power to liftgate 3 BS3 Blue...

Page 42: ... does not protrude beyond the width of the vehicle body Mount the provided Z brackets to the vehicle by either bolting or welding the brackets to the body Bolt or Weld to Body Z Brackets Screws Control Box Location 2 Route the 4 wire cab switch cable together with the battery cable and the 4 wire harness for the control power to the batteries along the sub wood Secure the cable every 12 against th...

Page 43: ...ox Face Run leads from Toggle Switch to 2 4 on Circuit Board Use Tie Straps to hold unused J11 Connector in safe location On Off Switch Tilt Lift Up Down Up Down OPERATING INSTRUCTIONS For questions regarding operation call 888 774 5844 ILF 33 44 55 To operate this liftgate read and understand the operating decals and manuals Make certain the platform is clear before operating the liftgate Liftgat...

Page 44: ...rom the vehicle floor or determine the best location as preferred by end user Fig 25 2 Route the cable from the liftgate up through the inside corner post or between the wall extrusions of the truck Use the wire clamp to secure the incoming cable to the surface Fig 26 3 Splice the cables from the liftgate to the hand held remote with the supplied butt connectors and seal all connections with heat ...

Page 45: ... table Power LED 3 Green Yellow 2 5 1 Function Socket Up Down 12V Hot Tilt Up Tilt Down 5 2 6 3 Green Yellow 3 2 14 2 4 3 Green 1 2 Socket to Control Wiring Table Control Board Socket Wiring Terminal Rear View Control Board Socket Set Screw 5 Wire the male plug to the hand held remote Remove the set screw and push out the wiring terminal from inside the plug housing Feed the wire from the control ...

Page 46: ...re drilled holes underneath for routing each harness Feed each cable harness through each foot control slot on the main section of the platform and route each harness as shown below Remove the cable cover to pull routed cable out of the platform Once the cable is out of the platform the lift arm is equipped with a bar that serves as a guide for the harnesses to be routed along and secured to Next ...

Page 47: ...ront Foot Control Harness J3 Plug Crimp Terminal P N 1358765 J3 Plug P N P 1358710 4 Test functionality of each foot control Follow the steps below DOWN Step on the front foot control and hold wait between one to three seconds before you step on the rear foot control UP Step on the rear foot control and hold wait between one to three seconds before you step on the front foot control IF BOTH SWITCH...

Page 48: ...he most important first step in troubleshooting the litgate Test voltage at the J11connection between wire 4 and ground min 10 V When testing for electricity on the individual solenoid plug at the cylinder always test voltage between the two prongs on the plug itself min 7 V After troubleshooting carefully close the rubber cap and secure it with the plastic strap CLOSE LOWER LIFT HACKBARTH When te...

Page 49: ...iagnosis mode activated Defect at motor solenoid detected during lifting Voltage V02 J1 pin 2 is missing defective fuse Defect at opening valve S3 S4 or motor relay detected during opening S5 valve detected during closing or motor solenoid defective S5 valve detected or defect at lowering valve S1 S2 Cab switch off on or disconnect bridge J11 2 4 Automatically when the valves are back to normal Au...

Page 50: ...tform up and down several times Lubricate and grease all points again 4 Wipe any excess grease and replace all red protector caps on zerks 6 PLCS 6 PLCS IN IN OUT Zerk Fitting 12 places 3 in the mount frame 3 in the cylinder platform area IN OUT Oil level in the power pack tank see marking inside of power pack reservoir IN Platform hinges and optional cart stops use WD 40 lubricant or equivalent ...

Page 51: ... S2 Release Valve for lowering function S3 and S4 Release Valve for tilt down function R1 and R2 Flow Restrictor located inside hose adaptor on lift cylinder R3 and R4 Flow Restrictor located inside hose adaptor on tilt cylinder S5 Shift Valve is activated on tilt up and lowering function R5 Restrictor Valve located in power pack Flow Divider is activated when fluid is going back into the power pa...

Page 52: ...1 ATG CAB Liftgate Shut Off Place Decal next to the On Off Switch in the Cab H 1 ATG WNG Warning Use handle to open Must be located underneath handle main section I 1 ATG FT Notice for Foot Control J Strip Conspicuity Tape Place tape along bumper K 1 ATG ILF Operating Instructions Place in control box L 1 85 0816 000 Operating Instructions Place on the curb side of vehicle body above control box S...

Page 53: ...on Manual Rev 1 1 53 Driver Side Curb Side A F C E D I H J J F C E G K L Flatbed Vehicle Curb Side Plate 60 0115 200 Plate Decal B Decal A Decal D Decal H Decal I Decal J Decal E Decal F Decal G Decal C Decal K Decal L Fig 27 ...

Page 54: ...r fasteners and are properly protected Circuit Breakers installed and wired per instructions Lights wired properly and operate per DOT State and Federal requirements All connectors at the control board are properly connected to their corresponding ports Measured battery voltages Flooded Batteries 12 6V AGM Batteries 12 8V Operational Inspection All decals are in place and legible per instructions ...

Page 55: ...ILF 33 44 55 Installation Manual Rev 1 1 55 ...

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