Palfinger ILU Under Slider 40 Owner'S Manual Download

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ILU

OWNER’S MANUAL

ECN-M1143 Rev. 1.5, Date 12-19-17 Part #90-1313-100

PALFINGER Liftgates, LLC. 15939 Piuma Ave., Cerritos, CA 90703

Tel (888)-774-5844 Fax (562)-924-8318

PALFINGER Liftgates, LLC. 572 Whitehead Road, Trenton, NJ 08619

Tel (609)-587-4200 Fax (609)-587-4201

Visit our website

www.palfinger.com

for

up to date information and notifications

If you received this product with damaged or missing parts,

Please contact PALFINGER Liftgates at (888)-774-5844

Summary of Contents for ILU Under Slider 40

Page 1: ...03 Tel 888 774 5844 Fax 562 924 8318 PALFINGER Liftgates LLC 572 Whitehead Road Trenton NJ 08619 Tel 609 587 4200 Fax 609 587 4201 Visit our website at www palfinger com for up to date information and notifications If you received this product with damaged or missing parts Please contact PALFINGER Liftgates at 888 774 5844 ...

Page 2: ... 13 5 2 Cross Test on Single Pole Plug Charge System 14 5 3 Lubrication 15 5 3 1 Lubrication Plan 15 5 3 2 Checking and Changing the Oil 17 5 3 3 Recommended Hydraulic Fluids 17 5 4 Decal Placement and Inspection 18 5 5 Quick Check List 20 6 Troubleshooting 21 6 1 Basic Function Check 21 6 1 1 LIFTGATE is competely DEAD No Clicking or Movement at all 21 6 1 2 ON OFF switch on but all functions are...

Page 3: ...uto Tilt Function 31 6 3 3 Level Out Activity 31 6 3 4 Lift Up Function 32 6 3 5 Slide In Function 32 7 Needed Information for Ordering Spare Parts and Repairs 33 7 1 Ordering Spare Parts 33 7 2 Repairs 33 8 Warranty 34 9 Contact Address 35 ...

Page 4: ...ly 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 actions are carried out by hydraulic cylinders m...

Page 5: ...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 interest of safety it is important that all operating pers...

Page 6: ...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 lo...

Page 7: ...t 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 without...

Page 8: ...enter This Manual has been designed for use in conjunction with the ILU 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 assistance in t...

Page 9: ...nter of Gravity of maximum Load Warning Lights Cart Stops Platform Push Pull Cylinders 2 Button Hand Control Control Box Circuit Board behind cover Liftarm Sensor B13 Platform Sensor B15 Foot Controls Slider Rails 3 Basic Parts in Detail 3 1 General View of Liftgate Figure 1 ILU Under Slider ...

Page 10: ...is rated up to a maximum load The point of maximum load is rated at a defined distance The center point of maximum load is at 24 for all ILU liftgates from start of Truck or Trailer Body as shown in Figure 2 Figure 2 Center Point of Load By increasing this distance the maximum load of the lift gate is decreasing An overview about the rating depending on the distance from the end of the platform is...

Page 11: ...ton on the right side of your Control Box Warning Lights will start flashing 2 Lowering down By rotating the lower button down you will lower the lift gate from its storage position 3 Slide out the liftgate Rotate the center button down to slide out the gate completely until you hit the stops 4 Unfold the platform manually by using the nylon strap 5 Check out auto tilt function Rotate the lower bu...

Page 12: ...ion 8 Sliding in Rotate the center button up to slide the lift gate underneath your vehicle till the gate is in its final position and does not more further back 9 Raising up By rotating the lower button up you will raise the lift gate up to its storage position 10 Turn off all functions by rotating the right button into the OFF position The flashing lights turns off ...

Page 13: ...l Looking at Front 4 2 Operation by Hand Held Remote Control Hand Controls are NOT weatherproof and are designed to be stored inside body in holster or in weatherproof box 1 2 Figure 4 Hand Held Remote Control with Plug Socket Wiring Button No 1 UP Button no 2 DOWN ...

Page 14: ...ill tilt up to preset position before raising IF BOTH SWITCHES ARE NOT ACTIVATED WITHIN THREE SECONDS START OVER 4 4 Operation by Wireless hand Held Remote optional 6 Way Wireless Remote Optional 1 Power the remote control unit using the ON OFF switch located on the rear side of the control 2 Reference illustration below for gate operation Tilt Down Tilt platform down Down Lower platform Up Raise ...

Page 15: ...been 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 Cart Stops Closed Position Cart Stops Open Position Platform Tip Push each cart stop down to close Push Down to Close Latch Cart Stop Closed Latch Cart Stop Open Platform Tip Platform Tip Latch ...

Page 16: ...ugh preventive care Recommended bases for inspection and maintenance Depending on use Daily Monthly Quarterly cleaning x general lubrication of pins and bushings x Platform Torsion Bar lubrication x general lubrication of Slider Rails with WD 40 and Push Pull Cylinder zerks with grease x oil level inspection x oil change x check hydraulic hoses and pipes for leaks x check controls and connections ...

Page 17: ...ntire 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 18: ... be between the two marks 5 and 7 when the platform is tilted down at ground level in stored position Use a good quality of hydraulic fluid ISO 32 Change oil 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 5 3 1 Lubrication Plan All bearing points must...

Page 19: ... 5 Lube Points Location of Grease Zerks 9 on each side 18 total Oil level in the power pack tank see marking inside of power pack reservoir Platform hinges Slide Rails and optional Cart Stops use WD 40 spray for lubrication Oil Change on Power Pack ...

Page 20: ... it up with hydraulic oil as shown on table 2 Figure 6 Power Pack Side View Figure 7 Power Pack Top View 5 3 3 Recommended Hydraulic Fluids TEMP RANGE BRAND 10 TO 150 F EXXON UNIVIS J26 MOBIL OIL DTE 13M CHEVRON AW MV32 ROSEMEAD MV 150 32 50 TO 150 F MOBIL DTE 13M SHELL AERO FLUID 4 EXTREME COLD TEMPERATURE USE MILITARY SPEC MIL H5606 Table 2 Recommended Hydraulic Fluids Hydraulic connections to c...

Page 21: ...ons placed on your Control Box C 1 ATG FT Notice for Foot Control if applicable D 2 ATG XXXX Max Capacity please check the serial number plate to find out your specific capacity E 1 ATG CAB Liftgate Shut Off must be placed next to the Shut Off Switch F 2 ATG WLH Warning liftgate can crush G 2 ATG CTN Caution Always stand clear of platform area H 1 ATG BKR Circuit Breaker Reset must be located at t...

Page 22: ...50 Owner s Manual Revision 1 5 19 The picture below will help you to place all decals visible in order to get maximum operational safety Decal A Decal C Decal D Decal B Decal F Decal G Decal J Decal K Decal L ...

Page 23: ... 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 addi...

Page 24: ...aults Please change oil after working on hydraulic unit removal of valves opening of cylinder etc There is a possibility of injury if somebody other than an authorized technician works on the electrical system Injuries are possible if short circuits are caused by tools on the main battery connections 6 1 Basic Function Check 6 1 1 LIFTGATE is competely DEAD No Clicking or Movement at all 1 Check t...

Page 25: ...in as shown on the decal ATG BKR next to your breaker or on battery box lid 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 batteries 4 Check the fuse at the power pack In the Hydraulic Power Unit next to the motor you will find two fuses Check for burned...

Page 26: ... any damages on mechanical or electrical parts such as damaged cables 6 1 2 ON OFF switch on but all functions are dead Possible malfunctions 1 Short in hand held remote or its wire unplug Hand Control 2 Short in control box wire remove plug J 30 After disconnecting plugs reboot board by unplugging J 1 for 5 seconds and plug it back Open this cap to check the fuses Replace fuse when metal bridge i...

Page 27: ...tch B 13 is not working unplug J 41 gate operates without sensor but loses auto tilt If gate is still not working take Truck Trailer to a repair station B 15 Sensor Make sure the wire strain relief is always parallel with top of the platform B 13 Sensor The B 13 switch is located on the curb side lift arm Set the switch in a horizontal level when the bottom of platform is 10 off the ground ...

Page 28: ... to ground Control Board Location Inside Resetable Circuit Breaker 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 NOTICE DO NOT attempt to jump in line fuses with other objects other than the specified fuse Do not increase the amperage rating of fuse Serious harm to the liftgate will re...

Page 29: ...er Single Pole Socket Auxiliary Batteries Ground Resettable Circuit Breaker 2Ga Power Cable From Liftgate 2Ga Ground Cable From Liftgate 2Ga Power Cable From Liftgate Resettable Circuit Breaker Dual Pole Socket Aux Batteries Ground Resettable Circuit Breaker 2Ga Ground Cable From Liftgate Single Pole Dual Pole ...

Page 30: ...Owner s Manual Revision 1 5 27 6 2 2 Electrical Schematic WIRELESS HANDCONTROL OPTIONAL WARNING LIGHTS Legend gn green bl blue br brown wt white ye yellow sw bk black gy green yellow Figure 9 Electrical Schematic ...

Page 31: ...wer 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 da...

Page 32: ... OFF ON POS 4 3 2 Hand Control TILT SLIDE LIFT up down in out up down 1 2 7 6 4 3 J32 81 80 5 1 2 3 4 gn ye 3 14 6 5 4 7 6 8 gn ye J30 J11 Backlight bulb Control Box 9 wire is not connected open end on both sides of the wire harness 10 wire harness ILUK Plus control box setup ...

Page 33: ...em 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 Datum 01 08 08 Hydraulic Schematic HACKBARTH ILU 40 50 15939 Piuma Ave Cerritos CA 90703 Figure 11 Hydrauli...

Page 34: ...ed to lower 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 cyli...

Page 35: ... push the lift cylinders to extend The platform raises up 6 3 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 res...

Page 36: ...ate the following information when making orders 1 Lliftgate model serial number 2 Designation and number of the spare part in accordance with the spare parts list 3 Designation and number marked on the individual component if available 7 2 Repairs Parts sent to PALFINGER Liftgates to repair must be accompanied by a letter in separate cover giving details and scope of the repairs required ...

Page 37: ...have been filled out in full The parts that are sent back to PALFINGER Liftgates marked with serial number and address become PALFINGER Liftgates property if the warranty claim is accepted All warranty claims must be received within 30 days of repair or replacement Including the following information 1 Liftgate model 2 Liftgate serial number 3 Description of problem 4 Itemized bill of repair with ...

Page 38: ...18 Fax 562 924 8318 E mail parts order customerservice PALFINGER com E mail technical support technicalservice PALFINGER com PALFINGER Liftgates LLC 572 Whitehead Road Suite 301 Trenton NJ 08619 Phone 609 587 4200 Fax 609 587 4201 E mail parts order customerservice PALFINGER com E mail technical support technicalservice PALFINGER com ...

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