Palfinger ILUK 33 Owner'S Manual Download Page 33

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ILUK 33/44/55/60

Owner’s Manual

Rev.1.5

8.3 Electrical System Codes

Check J-1 & J-2 power

cable at PC board

and battery for tight

connection, oxidation

and damage.

System OK / Control System: OFF

System OK / Control System: ON

Description:

Reason:

Code:

System OK / Control System: OFF

System OK / Control System: ON

System OK /

Control System: OFF
System OK /

Control System: ON

Check J-1 & J-2 power

cable at PC board

and battery for tight

connection, oxidation

and damage.

Solution 1:

Solution 2:

Solution 3:

Solution 4:

Check fuses at power

pack

Check fuse holder

Replace fuse with same

amp fuse

Low Voltage

General Short in electric wiring

Defect in motor solenoid

during lifting

Fuse 15A damaged on power

pack (J1, Pin 2)

During opening, an error was

recognized on the valve spool for

opening (S3/S4) or at the motor

solenoid. NOTE: ONLY APPLIES

TO ILK CANTILEVER LIFTGATE.

During closing, an error was

recognized on the motor solenoid

or on the valve spool S-5.

NOTE : ONLY APPLIES TO ILK

CANTILEVER LIFT GATE.

Error diagonstic mode active

Attached service plug

Check the battery

condition / battery

charged

Check the battery

condition / battery

charged

Check the battery

condition / battery

charged

Unplug wires one by

one, check for correct

plug location

Check the battery

condition / battery

charged

Motor could have worn

carbon brushes / motor

could be bad

Check ohm reading

of the coils

Check ohm reading

of the coil motor

solenoid

Repair cables,

connections, check for

burnt or crushed wires

Possible short in Thermo

Switch inside motor

Bypass and test, replace

Thermo Switch

Change coils or

cables

Change coils or

cables

Power consumption J1 pin 3 too

high; ohm reading J1 pin 12 has

changed

Defective fuse J1 Pin 2

Power consumption J1 Pin 3

to high; ohm reading J4 pins 14

have changed

General power consumption

to high

Power consumption J1 Pin 3

to high

Power consumption J11 Pin 1

to high

Short in cab Switch, control

system

Voltage J1 Pin 2 too low

Check J-1 & J-2 power

cable at PC board

and battery for tight

connection, oxidation

and damage.
Check J-1 & J-2 power

cable at PC board

and battery for tight

connection, oxidation

and damage.
Check J-1 & J-2 power

cable at PC board

and battery for tight

connection, oxidation

and damage.

Check J-1 & J-2 power

cable at PC board

and battery for tight

connection, oxidation

and damage.

NOTE: ILK, B-15 Sensor wire points

toward ground when platform

strored vertical
NOTE: ILF, ILU, ILUK b-15 sensor

wire points toward front of vehicle

when platform is up at bed level

NOTE: B-13 sensor wire points

toward front of vehicle

NOTE: Purple side of sensors

always face outward, where you

can see purple

To Clear Code:

1. Unplug J-11 and plug

back in

2. Cab switch off and on

to clear code

Emergency mode active (all logic

fuctions and comfort fuctions are

switched off)

Activate by pressing OPEN and

LOWERING button (and Second

Hand if in use) simultaneously

for over 10s

Deactivate by turning

cab switch or on off

switch OFF then back

During lowering, an error was

recognized on S-1/S-2 lowering

valves or valve spool S-5

Resistance J1 pin 12 has

changed; ohm reading J4

pins 15 have changed

Check resistance of the

coils

Change valve coils and

cables

Check ohn reading of

the coils

Change coils or

cables

Possible short in diode

jumper wire on Motor

Solenoid: Remove

Jumper

Check cab cut off/

warning light cable for

damange

Short on warning lights

Power consumption J3 Pin 7

to high

Check J-1 & J-2 power

cable at PC board

and battery for tight

connection, oxidation

and damage.

Check warning light

cables for damange

Platform sensor (B-15): Broken

wire, short

J41-C shorted; J41 pin BLUE:

wire getting more than 5 Volts

(right upper location J41)

Check adjustment B-15

platform

Unplugged, plugged in

wrong location

Change B-15 platform

sensor

To temporary by-pass,

jump Black to Blue

Liftarm sensor (B-13): Broken

wire, short

J41-C shorted; J41 pin BLUE:

wire getting more than 5 Volts

(right upper location J41)

Check adjustment B-13

Check sensor for signal

Blue wire with platform

10"-12" off ground

Change B-13 liftarm

sensor

Code Display

Summary of Contents for ILUK 33

Page 1: ...OWNER S MANUAL ILUK 33 3300 lbs Capacity ILUK 44 4400 lbs Capacity ILUK 55 5500 lbs Capacity ILUK 60 6000 lbs Capacity 06 18 ...

Page 2: ...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 Parts Order liftgateparts palfinger com 15939 Piuma Ave Cerritos CA 90703 Tel 888 774 5844 Fax 562 924 8318 572 Whitehead Road Trenton NJ 08619 Tel 609 587 4200 Fa...

Page 3: ...Platform Cart Stop Operation Optional 20 6 5 Foot Controls Operation Optional 21 7 Preventive Maintenance and Quick Check 22 7 1 Maintenance and Care 22 7 2 Lubrication 23 7 3 Checking and Changing the Oil 24 7 4 Decal Placement and Inspection 25 7 5 Quick Check List 27 8 Troubleshooting 28 8 1 1 Liftgate will not power on 28 8 1 2 ON OFF Switch is On But All Functions are Dead 31 8 1 3 Warning Li...

Page 4: ...ion 39 8 8 5 Slide In Function 39 8 9 ILUK Push Pull Valving 40 9 Needed Information for Ordering Spare Parts and Repairs 42 9 1 Ordering Spare Parts 42 9 2 Repairs 42 10 Warranty 42 11 Contact Address 43 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 choosin...

Page 5: ...ILUK 33 44 55 60 Owner s Manual Rev 1 5 5 1 Manual Updates Revision Description v1 5 Reformatted manual to standard format Revised Liftgate Operiational Instructions Updated Electrical Schematic ...

Page 6: ...t platform The Hydraulic Power Unit HPU is easily accessible for service and exchange The whole assembly slides out and can be serviced at that point To exchange the Hydraulic Power Unit HPU two hoses and the battery cables need to be disconnected The platform folded in half is supported by two arms linked with a torsion tube The platform in a stored position acts as the under ride guard Lifting a...

Page 7: ...nager s responsibility to educate the operator on the liftgate and its intended use The operator s attention should be drawn to the permitted load limits and an understanding of the operation to ensure the safety throughout the operation ONE MAN OPERATION Never let an outsider operate the liftgate while you are handling the cargo A misunderstanding can result in serious personal injury In the inte...

Page 8: ... 6 Never stand in move through or allow anyone else to stand in or move through the area in which the lift operates including that area in which a load might fall 7 This is not a passenger lift Do not ride the lift with unstable loads or in such a manner that a failure would endanger you The lift is not equipped with a back up system to prevent falling cargo in the event of a failure The maximum l...

Page 9: ...ot avoided 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 withou...

Page 10: ...vice Center This Manual has been designed for use in conjunction with the ILUK series liftgate only which is designed for different capacities You have different options to determine the type of your Liftgate 1 Refer to the serial number tag on the Liftgate 2 Ask your employer or lessor 3 Call your PALFINGER Liftgates Authorized Service Center for assistance 4 Call PALFINGER Liftgates for assistan...

Page 11: ...Power Unit Platform Control Box Wire Management Bar w Rings Liftarms Tilt Cylinders Push Pull Cylinders Bracket Rapid Mount Bolt On RMB Tray 3 5 8 or 10 H Slider Rails Lift Cylinders Control Board PCB Push Pull Cylinders w Tray Platform Bumpers Rapid Mount Bolt On RMB Tray 3 5 8 or 10 H Warning Lights Foot Controls Slide Rail Stops ...

Page 12: ... Pull Cylinders w Tray Tilt Cylinders Liftarms Hydraulic Power Unit Control Board PCB Wire Management Bar w Rings Control Box w Mount Brackets Slider Rails Push Pull Cylinders Bracket Slide Rail Stops Mounting Brackets w Hardware Mount Plates Tilt Cylinders Platform Warning Lights Foot Controls Slide Rail Stops ...

Page 13: ... maximum load is at 24 from the rear of the bed extension out to the platform 24 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 24 36 48 60 72 84 10 20 30 40 50 60 70 80 90 100 Distance From Body inches Capacity Capacity 100 at 24 80 at 36 60 a...

Page 14: ...als Make certain the platform is clear before operating the lift Liftgate shut off switch must be turned off when liftgate is not in use Keep platform in horizontal position when loading and unloading Do not overload refer to capacity decals Loading Position Lower platform Slide out liftgate Unfold platform Storage Position In down position fold up platform tip Slide in liftgate Raise platform Max...

Page 15: ...Floor Sill Strap Handle 5 Use the Lift Up switch to raise the platform up to bed level until the liftarms are in contact with the liftarm upstops Longsill Chassis Wooden Spacer s Crossmembers Floor Sill Tilt Slide Lift 6 Center the load on the platform 24 away from the rear of the vehicle sill Longsill Chassis Wooden Spacer s Crossmembers Floor Sill Load 24 ...

Page 16: ...Lift Down switch to lower the platform until the ground rollers on the platform reach the ground NOTE Maintaining the Lift Down switch down will cause the platform to tilt down Longsill Chassis Wooden Spacer s Crossmembers Floor Sill Load Tilt Slide Lift ...

Page 17: ...bers Floor Sill Tilt Slide Lift 2 Use the Lift Up switch to raise the platform approximately 10 from the ground Fold the tip manaully using the strap and secure the tip to the main with same strap Longsill Chassis Wooden Spacer s Crossmembers Floor Sill 10 3 Use the Slide In switch to store the gate Longsill Chassis Wooden Spacer s Crossmembers Floor Sill Tilt Slide Lift ...

Page 18: ...ding operation call 888 774 5844 ILUK ILU To operate this liftgate read and understand the operating decals and manuals Make certain the platform is clear before operating the lift Liftgate shut off switch must be turned off when liftgate is not in use Keep platform in horizontal position when loading and unloading Do not overload refer to capacity decals Loading Position Lower platform Slide out ...

Page 19: ...ing up 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 liftgate 2 Power the remote by using the ON OFF switch on the rear of the control 3 Each function has a separate button Functions are displayed below 4 After finishing using the gate switch the pow...

Page 20: ...n moved from its original position 2 To close the cart stops push the cart stop latch inward towards the street side After the latch is in place close each cart stop by pushing each stop down Latch Cart Stop Closed Latch Cart Stop Open Cart Stops Open Position Platform Tip Platform Tip Cart Stops Closed Position Latch Cart Stop Open Cart Stops Open Position Platform Tip Note One latch is used for ...

Page 21: ...e switches until the platform starts tilting Raise Platform Step on the rear foot control and hold wait three seconds before stepping on the front foot control The platform will tilt up to preset postion before raising IF THE PLATFORM IS NOT RESPONDING TO THE CONTROLS WITHIN THREE SECONDS REPEAT STEPS ABOVE Front Rear Front Foot Control RearFoot Control Lower Platform Raise Platform Front Foot Con...

Page 22: ...ive care Recommended bases for inspection and maintenance Depending on use Daily Monthly Quarterly Cleaning General lubrication of pins and bushings General lubrication of Slider Rails with WD 40 and Push Pull Cylinder zerks with grease Oil level inspection Oil change Check hydraulic hoses and pipes for leaks Check controls and connections Check platform retention bar Check pins and pin retaining ...

Page 23: ...l at least once a year preferably in the fall before the weather gets cold The operation of the lift gate will accumulate condensation and some dirt which can interfere with the lift gate functions Oil reservoir inside main tube Pull out tray to check and refill oil 4 zerks 2 Lift Cylinder 1 Lift arm 1 Tilt Cylinder Platform Hinges Cart Stops If installed 3 zerks 1 Tilt Cylinder 1 Liftarm 1 Lift C...

Page 24: ... 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 2 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 2 Oil Drain Bolt Oil Filler When changing or adding fluids...

Page 25: ...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 PLAT Warning 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 WNG Warning Use handle to open must be located underneath handle main section J 1 ATG FC Foot Controls Option...

Page 26: ... your helper s body to be placed under through or around any portion of the moving lift gate or in a position that would trap them between any parts when the lift gate is operated 7 This lift gate is intended for loading and unloading of cargo only Do not use this lift gate for anything but it s intended use The lift gate is not equipped with a back up system to prevent falling in the event of a f...

Page 27: ...e air out of the system by operating all functions several times 7 Check all electrical connections Clean and protect battery terminals and check for tightness 8 Inspect all the terminals on the solenoid operated valves at the port of the cylinder Lubricate the terminals for better protection from oxidation if needed Please check the valve block on the back of the main tube and its connections add...

Page 28: ...onnections 8 1 1 Liftgate will not power on 1 Check the shut off switch Turn ON the ON OFF switch located inside the vehicles cab Truck or control box Trailer ON OFF Switch Location for Trucks ON OFF Switch Location for Trailers On Off Switch Up Down Tilt Lift Slide In Out Up Down For questions regarding operation call 888 774 5844 ILUK ILU To operate this liftgate read and understand the operatin...

Page 29: ...r reset tab is exposed push the tab back in as shown Circuit Breaker Location Buss Bar Circuit Breaker at Truck Batteries or Auxiliary Battery Box Reset Tab RESET 3 Are the vehicle batteries charged Check batteries and the truck trailer charging system Start truck and run engine in fast idle for charging the batteries If liftgate starts working recharge and load test batteries Measure battery volt...

Page 30: ... on hydraulic power unit OK Is the ground connection from the liftgate to vehicle properly grounded 6 Check the oil level in the hydraulic power unit The power unit is located inside the enclosure mounted on the mount frame To access the oil reservoir remove the enclosure cover The oil must be 1 down from the top of the reservoir 7 Are there any damages on mechanical or electrical parts such as da...

Page 31: ...isconnecting plugs reboot board by unplugging J 1 for 5 seconds and plug it back 8 1 3 Warning Lights ON after ON OFF Switch is Turned OFF 1 B 15 Sensor is not working Make sure the wire strain relief is alwas parallel with the top of the platform 8 1 4 Platform Tilts Down Before it Reaches The Ground 1 Adjust B 13 liftarm sensor 2 B 13 is not working Unplug J41 Gate operates without sensor but lo...

Page 32: ...ttable Circuit Breaker Ground 2Ga Power Cable From Liftgate 2Ga Ground Cable From Liftgate In Line Fuse Wires 2 and 4 go to postitive Wires 1 and Gr Yl go to ground Wiring Diagram Truck Resettable Circuit Breaker Single Pole Socket Auxiliary Batteries Ground Resettable Circuit Breaker 2Ga Power Cable From Liftgate 2Ga Ground Cable From Liftgate In Line Fuse Wires 2 and 4 go to postitive Wires 1 an...

Page 33: ...Pin 2 too low Check J 1 J 2 power cable at PC board and battery for tight connection oxidation and damage Check J 1 J 2 power cable at PC board and battery for tight connection oxidation and damage Check J 1 J 2 power cable at PC board and battery for tight connection oxidation and damage Check J 1 J 2 power cable at PC board and battery for tight connection oxidation and damage NOTE ILK B 15 Sens...

Page 34: ... Port Designation J1 Power Pack J1 A Valve J2 Not Used J3 Warning Lights Foot Controls on Platform J4 Valves J11 On Off Switch J30 Control Box J31 Hand Held Remote J32 Not Used J41 A B 13 Sensor J41 B Not Used J41 C B 15 Sensor J42 Valves JB Not Used JK Not Used JP PC Diagnosis ...

Page 35: ...entire 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...

Page 36: ...ILUK 33 44 55 60 Owner s Manual Rev 1 5 36 8 6 Electrical Schematic 15939 Piuma Ave Cerritos CA 90703 ILUK Electrical Schematic 013033 02 01 Power Pack Circuit Board Control Box ...

Page 37: ...ll valve block are double acting release valves They have to be activated for fluid to go through them in either direction To slide out S8 is activated to allow fluid to both sides of retractable cylinders To slide in S7 is activated to allow fluid to piston rod side of retractable cylinders Functions Lift M S1 S2 Lower S1 S2 S5 S11 Tilt Up M S5 Tilt Down S3 S4 Slide Out M S8 Slide In M S7 ...

Page 38: ...down by gravity It will push the hydraulic oil out of the lift cylinder into the reservoir The oil passes the solenoid release valves S1 and S2 It also has to pass the energized S11 valve in the back of the mount frame and the shift valve S5 at the pump When the platform touches the ground the auto tilt function will get activated B 13 Solenoid release valves S3 and S4 at the tilt cylinders will b...

Page 39: ...o push the lift cylinders to extend The platform raises up 8 8 5 Slide In Function 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 at the cylinder The energized valve S7 is allowing the oil at the bottom of the piston rod to get back through the S5 into the re...

Page 40: ...ILUK 33 44 55 60 Owner s Manual Rev 1 5 40 8 9 ILUK Push Pull Valving ...

Page 41: ...59 180 125 138 200 223 282 315 7 8 129 144 322 355 454 501 1 188 210 483 541 682 764 Metric Fasteners Fastener Size Class 8 8 Torque Nm Class 10 9 Torque Nm Class 12 9 Torque Nm Coarse Fine Coarse Fine Coarse Fine M5 5 75 8 1 9 7 M6 9 9 14 16 5 M7 16 5 23 27 M8 24 34 40 M8x1 25 35 42 M10 48 67 81 M10x1 25 49 68 82 M12 83 117 140 M12x1 25 88 125 150 M14 132 185 220 M14x1 5 140 195 235 M16 200 285 3...

Page 42: ... Palfinger 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 s...

Page 43: ...ntact Address 15939 Piuma Ave Cerritos CA 90703 Phone 562 924 8218 Fax 562 924 8318 E mail parts order liftgateparts palfinger com 572 Whitehead Road Trenton NJ 08619 Phone 609 587 4200 Fax 609 587 4201 E mail parts order liftgateparts palfinger com ...

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