Palfinger ILP 25 Owner'S Manual Download

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ILP 25/33

Owner’s Manual

Rev.1.4

Table of Contents

Manual Updates ........................................................................................................................ 5

Safety Information .................................................................................................................... 6

2.1

General Safety .............................................................................................................. 7

Important Information .............................................................................................................. 8

3.1

Improper Useage .......................................................................................................... 9

General View of Liftgate ........................................................................................................... 10

4.1

ILP Liftgate Overview .................................................................................................... 10

Maximum Load and Placing of Load on Platform .................................................................. 11

Operation of Liftgate ................................................................................................................ 12

6.1

Operation by Toggle Switch/Hand Held Remote Control ............................................... 12

6.2

Hand Held Remote Control (Optional) ........................................................................... 14

6.3

Wireless Hand Held Remote (Optional) ........................................................................ 14

6.4

Cart Stops Operation (Optional) .................................................................................... 15

Preventive Maintenance and Quick Check ............................................................................. 17

7.1

Maintenance and Care .................................................................................................. 17

7.2

Lubrication .................................................................................................................... 18

7.3

Checking and Changing the Oil ..................................................................................... 19

7.3.1

Recommended Hydraulic Fluids Table ............................................................ 20

7.4

Decal Placement and Inspection ................................................................................... 21

7.5

Quick Check List ........................................................................................................... 23

Troubleshooting ....................................................................................................................... 23

8.1

Liftgate will not power on. .............................................................................................. 24

8.2

Liftgate does not Lower Down ....................................................................................... 26

8.3

Liftgate does not Lift Up ................................................................................................ 27

8.4

Electrical Wiring

– Batteries – Truck/Trailer ................................................................... 28

8.5

Cross Test on Single Pole Plug Charge System ........................................................... 29

8.6

Electrical Schematic (Gravity Down ) ............................................................................ 30

8.7

Electrical Schematic (Power Down ) ............................................................................. 31

8.8

Hydraulic Schematics (Gravity Down) ........................................................................... 32

8.9

Hydraulic Schematics (Power Down) ............................................................................ 33

Needed Information for Ordering Spare Parts and Repairs ................................................... 34

9.1

Ordering Spare Parts .................................................................................................... 34

9.2

Repairs ......................................................................................................................... 34

Summary of Contents for ILP 25

Page 1: ...OWNER S MANUAL ILP 25 2500 lbs Capacity ILP 33 3300 lbs Capacity 02 19 ...

Page 2: ...hts reserved Information in this document is subject 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 15939 Piuma Ave Cerritos CA 90703 Tel 888 774 5844 Fax 562 924 8318 572 Whitehead Road Trenton NJ 08619 Tel 609 587 4200 Fax 609 587 4201 ...

Page 3: ...nce and Quick Check 17 7 1 Maintenance and Care 17 7 2 Lubrication 18 7 3 Checking and Changing the Oil 19 7 3 1 Recommended Hydraulic Fluids Table 20 7 4 Decal Placement and Inspection 21 7 5 Quick Check List 23 8 Troubleshooting 23 8 1 Liftgate will not power on 24 8 2 Liftgate does not Lower Down 26 8 3 Liftgate does not Lift Up 27 8 4 Electrical Wiring Batteries Truck Trailer 28 8 5 Cross Test...

Page 4: ...nty 34 11 Contact Address 35 Company Information Company Name Advisor Name Vehicle Year Make Model Liftgate Information Liftgate Serial Number Liftgate Model Number Date of Purchase Date of Installation Thank you for choosing Palfinger Liftgates ...

Page 5: ...anual Updates Revision Description v1 1 Changed product name from PLP to ILP v1 2 Revised Sections 13 9 13 10 Toggle switch wire colors updated v1 3 Updated Sections 8 6 8 7 v1 4 Updated pictorials throughout manual to match actual product ...

Page 6: ...voided could result in death or serious injury CAUTION indicates a potentially hazardous situation which if not avoided may result in 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 th...

Page 7: ...ad and are familiar with the operation instructions If you do not have a copy of the instructions please obtain them from your employer distributor or lessor as appropriate before you attempt to operate the lift 2 Be certain the vehicle is properly and securely stopped before using the lift 3 Always maintain the liftgate and inspect it for damage before usage If there are signs of improper mainten...

Page 8: ...stallation operation or maintenance at 888 774 5844 This owner s manual applies to the following models ILP 25 33 Important notes The electric supply is taken from the vehicle battery If the vehicle battery is not sufficient an auxiliary battery kit needs to be installed The electric control power is secured via a 15 Amp fuse and an on off switch located inside the cab Trailer applications have an...

Page 9: ...technical support contact Palfinger Liftgates or an authorized Palfinger service center www palfinger com 3 1 Improper Useage Some examples of improper use of the liftgate may include but are not limited to Using the liftgate as an elevating work platform Using the liftgate to push pull or tow loads or other objects Using the liftgate to carry people Only the operator may travel on the platform Us...

Page 10: ...mper Hitch Bumper Center Bumper Hydraulic Power Unit Liftarm Parallel Arm Platform Cart Stops Optional Single Action or Double Action Lift Cylinders Springs Hydraulic Power Unit Platform Roll Off Wheels Bolt On Mount Plates Mount Frame Bed Extension No spring installed on left side for 42 and 48 aluminum platforms only ...

Page 11: ...t of maximum load is at 24 from the rear of the bed extension out to the platform Fig 2 24 Vehicle Load By increasing this distance the maximum load of the liftgate is decreasing An overview about the rating depending on the distance from the end of the platform is shown in the following load diagram 18 24 30 36 42 48 54 60 66 72 78 84 90 10 20 30 40 50 60 70 80 90 100 Distance From Body inches Ca...

Page 12: ...r Trucks Rocker Switch Toggle Switch ON OFF Switch Location for Trailers 2 Use the Down function of the toggle switch to lower the gate from the stored position Fig 5 until the platform rest on the wheel Fig 6 Down Up 3 Identify the type of platform installed Steel and aluminum platforms have different safety features Steel platforms have a safety chain that secure the tip to the main Fig 7 Alumin...

Page 13: ...e bed extension Fig 11 Use the toggle switch to lift the platform up and down Fig 12 To tilt the platform down continue holding the toggle switch down until the platform begins to tilt Toggle up to tilt the platform up parallel the ground Down Up 24 Load Load To Store Liftgate 1 Raise platform approximately 16 from the ground fold the tip manually using the handle strap and secure the tip to the m...

Page 14: ...ilt Up at Ground Level Press and hold the button until the platform starts tilting up Note The tilt up function can also be achieve with the standard toggle switch by performing the same procedure Lift DOWN Lift UP White Button Black Button Tilt Up at ground level Tilt Down at ground level 6 3 Wireless Hand Held Remote Optional 1 Read the wireless remote owner s manual before operating the liftgat...

Page 15: ...riginal position Fig 15 2 To close the cart stops push the cart stop latch inward towards the street side Fig 16 After the latch is in place close each cart stop by pushing each stop down Latch Cart Stops Closed Position Platform Tip Cart Stops Open Position Platform Tip Latch Latch Push each cart stop down to close Platform Tip Cart Stop Open Cart Stop Closed Push Down to Close Fig 14 Fig 15 Fig ...

Page 16: ... been pushed Fig 18 2 To close the cart stop push and hold each cart stop down in close position and lock each cart stop with the retaining latch Fig 19 Cart Stops Closed Position Platform Tip Push each cart stop down to close Platform Tip Platform Tip Cart Stops Open Position Push Down to Close Cart Stop Open Cart Stop Closed Retaining Latch Retaining Latch Retaining Latch Note One latch on each ...

Page 17: ...liftgates longevity it is important to maintain and perform preventive care as indicated below Recommended bases for inspection and maintenance Depending on use Daily Monthly Quarterly Cleaning x General lubrication of pins and bushings x Oil level inspection x Oil change x Check hydraulic hoses and pipes for leaks x Check controls and connections x Check pins and pin retaining bolts x Check batte...

Page 18: ...d in accordance with the maintenance intervals Reminder Lubricate all points with the platform at ground level Platform Hinges Cart Stops If installed 4 zerks 1 Cylinder 2 Lift arm 1 Parallel arm 4 zerks 1 Cylinder 2 Liftarm 1 Parallel arm 4 zerks 1 Cylinder 1 Parallel arm 2 Shackle 4 zerks 1 Cylinder 1 Parallel arm 2 Shackle Open enclosure to check and refill oil Grease Location of Grease Zerks 8...

Page 19: ...ommended fluid from the 6 3 1 fluids table To change fluid 1 Unscrew the Oil Drain Bolt and let the fluid drain out of the reservoir into an approved cointainer When reservoir is empty fill the reservoir up between 1 from the top of the reservoir Change oil at least once a year preferable in the fall before the weather gets cold 2 Place the cover back on to the Hydraulic Power Unit enclosure Motor...

Page 20: ...Flash Point 128 C 262 F Density 15 C 59 F kg L 0 834 Viscosity cSt 40 C SUV 100 F cSt 100 C SUV 210 F cP 50 C 58 F 13 0 69 7 4 95 42 5 1 310 When changing or adding fluids it is highly recommended to use Hydrex MV Arctic 15 fluid however the alternatives fluid brands listed below can be used Alternative Fluids Temperature Range Fluid Brand 30 to 150 F EXXON UNIVIS J26 MOBIL DTE 13M CHEVRON AW MV32...

Page 21: ...ck the serial number plate to find out the gates specific capacity E 1 ATG RESET Circuit Breaker Protection F 2 ATG WLH Warning liftgate can crush G 2 ATG CTN Caution Always stand clear of platform area H 1 ATG CAB Liftgate Shut Off Place Decal next to the On Off Switch in the Cab I 1 ATG UD Toggle Switch Decal At post for trucks At strut or trailers J 1 ATG WNG Warning Use handle to open must be ...

Page 22: ...ILP 25 33 Owner s Manual Rev 1 4 22 Curb Side A B D E G I I F G D Driver Side J F Decal B Decal E Decal D Decal F Decal G Decal J Decal H Decal I Decal A Decal C ...

Page 23: ...id operated valves at the port of the cylinder Lubricate the terminals for better protection from oxidation if needed 9 Grease all zerks on the liftgate and make sure they all take grease Sometimes it helps to operate the liftgate while you do this 10 Test all the liftgate functions 11 Check the function of the pressure relief valve 12 When doing daily checks and you find any kind of damage that c...

Page 24: ...h ON OFF Switch Location for Trailers 2 Check the circuit breaker at the main batteries Every truck has a circuit breaker on top of the main batteries or if you have an auxiliary battery kit as shown in the illustration below Fig 20 If circuit breaker reset tab is exposed push the tab back in as shown Fig 21 Circuit Breaker Location Buss Bar Battery or Battery Box Mount Reset Tab RESET Circuit Bre...

Page 25: ...e 15 Amp at solenoid Replace with same amperage fuse when necessary NOTICE DO NOT attempt to jump in line fuse s with other objects other than the specified fuse s DO NOT increase the amperage rating of fuse Serious harm to the liftgate will result when standard practices are not followed Solenoid 5 Is the connection to ground on hydraulic power unit OK Is the ground connection from the liftgate t...

Page 26: ...maged If the voltmeter shows 0 volts the cable is damaged c Remove the plastic cap of the release valves keep coil in place hold a screwdriver close to steel valve stem while pressing the down function on the toggle switch if screwdriver did not get magnetically pulled towards the valve the coil is bad 30 Ft x 2 ga Battery Cable 150 amp Circuit Breaker 12V Power Supply MBB Germany Cable 3273863 Sp...

Page 27: ...power on large positive motor stud If no power is present either the motor or the brushes are bad If there is no power at the motor stud check the connection to the solenoid If gate is still not working take truck trailer and gate to an authorized repair station 30 Ft x 2 ga Battery Cable 150 amp Circuit Breaker 12V Power Supply MBB Germany Cable 3273863 Spade Connectors with housing Yellow Green ...

Page 28: ...cified fuse Do not increase the amperage rating of fuse Serious harm to the liftgate will result when standard practices are not followed Main Batteries Resettable Circuit Breaker Ground 2Ga Power Cable From Liftgate Resettable Circuit Breaker Single Pole Socket Auxiliary Batteries Ground Resettable Circuit Breaker 2Ga Power Cable From Liftgate Wiring Diagram Truck Wiring Diagram Single Pole Trail...

Page 29: ...re circuit on tractor including ground 2 Trailer Test Ground battery load tester on trailer chassis point C Connect positive cable on positive pole of single pole plug receptacle on trailer B Run load test This will test entire circuit on tractor including circuit breakers and ground between trailer batteries and trailer chassis 3 Tractor and Trailer Charging system test while connected Ground bat...

Page 30: ... Cable 3273863 Spade Connectors with housing Yellow Green Ground Brown Power Blue Load Brown Power Blue Load Yellow Green Ground ON OFF Switch Truck Installation Power 4 Blue Raise 5 Brown Lower 6 Yellow Green 70 0312 002 Yellow Green Ground Toggle Switch Power Load Ground Lower Valve s at Cylinders 2 Button Hand Held Remote Optional Piggy back with Toggle Switch ON OFF Switch Trailer Installation...

Page 31: ...tch Ground Lower Solenoid Black Ground Lower Solenoid Black Lower Valve S1 Lower Valve S2 Shift Solenoid Yellow Shift Valve Ground Power 15A Fuse Torque Specifications Starter Solenoid M6 1 3 ft lbs 1 7 Nm M8 3 ft lbs 4 Nm Electric Motor M8 6 3 ft lbs 8 5 Nm Harness Splice Connectors Lower Raise 70 0312 002 Yellow Green Ground 2 ga Ground Cable at Enclosure Optional 2nd toggle Cut ends off of togg...

Page 32: ... on liftgate S N PT 10598 15939 Piuma Ave Cerritos CA 90703 R1 R2 S1 S2 Lift Cylinder Lift Cylinder S1 S2 Release Valve for Lowering R1 R2 Flow Restrictor for limiting lower speed Raise M Lower S1 S2 Port Pump Unit Relief Valve 2850 psi Filter Pump Reservoir Tank Motor Breather A M Pilot to Close Check Valve Pump Unit M 3441 0104 ...

Page 33: ... Pump Reservoir Tank Motor Breather S5 Shift Valve A B R1 R2 S1 S2 Lift Cylinder Lift Cylinder S1 S2 Release Valve for Lowering R1 R2 Flow Restrictor for limiting lower speed S5 Shift Valve is activated upon LOWER function only Pilot to close check valve is NOT used on Power Down Raise M Power Down M S1 2 S5 M Pilot to Close Check Valve 2 Position 4 way Valve Pump Unit M 3441 0104 MBB Toggle Contr...

Page 34: ...finger Liftgates has been able to determine that the warranty claim is justified as defined by its warranty conditions Palfinger Liftgates does this by inspecting the defected parts which are sent back to Palfinger Liftgates freight prepaid as well as the written description of the problem which must have been filled out in full The parts that are sent back to Palfinger Liftgates marked with seria...

Page 35: ...18 Fax 562 924 8318 E mail parts order liftgateparts palfinger com E mail technical support technicalapplications palfinger com 572 Whitehead Road Trenton NJ 08619 Phone 609 587 4200 Fax 609 587 4201 E mail parts order liftgateparts palfinger com E mail technical support technicalapplications palfinger com ...

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