90-0415-000 ILK18 IM v1.0 0415 · TABLE OF CONTENT ILK-18 INSTALLATION MANUAL Revision 1.0 - 3 -...
Transcript of 90-0415-000 ILK18 IM v1.0 0415 · TABLE OF CONTENT ILK-18 INSTALLATION MANUAL Revision 1.0 - 3 -...
ILK-18
INSTALLATION MANUAL & CHECK-OFF SHEET
ECN-M0578 Rev. 1.0, Date 04-06-15 Part #90-0415-000
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 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
TAB
R
TaTab
1
2
3
4
5
6
7
8
BLE OF CONT
Revision 1.0
able of coble of conte
Impor
Dimen
2.1
Chass
3.1
3.2
Gate a
4.1
4.2
4.3
4.4
4.5
4.6
4.7
4.8
Electr
5.1
5.2
5.3
5.4
5.5
5.6
Lubric
6.1
Check
Instal
8.1
8.2
8.3
8.4
TENT
0
ontent ent ..............
rtant Notes:
nsion Sheet
Installatio
sis and Bod
Flip-Up d
Swing do
and Platform
Sill Prepa
Installatio
Platform
4.3.1 A
4.3.2
Installatio
Setting a
Setting a
Installatio
Finalize I
rical Installa
Main Pow
On-off sw
Remote H
Wiring Di
Connecto
Hydraulic
cation and
Decal Pla
k Off Sheet
lation Refer
Mercedes
Mercedes
Ford Tran
Ford Tran
...................
: ..................
t .................
on Dimensio
dy Preparat
door & Full-d
oor applicatio
m Installatio
aration ........
on with moun
Installation .
Attach platfo
Installation a
on without m
nd Operatio
nd Operatio
on of left and
nstall ..........
ation ...........
wer Connect
witch installa
Hand Contro
iagrams ......
or Overview
c Schematic
Final Inspe
acement and
...................
rence .........
s Benz, Whe
s Benz, Whe
nsit, Wheelb
nsit, Wheelb
...................
...................
...................
ons ILK 18 ...
ion for spec
door seal kit
ons ..............
on ...............
...................
nting fixture
...................
orm to liftarm
and Adjustin
mount fixture
n of B-16 Se
n of B-13 Se
d right Up St
...................
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tions ............
ation .............
ol Installation
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ction ..........
d Inspection
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eelbase 144
eelbase 144
base 123“-15
base 156“, E
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cial applica
installation .
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m .................
ng the tilt cyli
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ensor ..........
ensor ..........
tops ............
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n .................
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4“-170“ ........
4“-170“ ........
56“ ..............
Extended Ch
ILK
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ations .........
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assis, 2014
K-18 INSTAL
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ANUAL
- 2 -
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TABLE OF CONTENT ILK-18 INSTALLATION MANUAL
Revision 1.0 - 3 -
Recommended Tools For Installation
Metric Wrench Set Basic Screwdrivers Pliers Wire Crimp Pliers
Test Light Snap Ring Pliers Hammer Metric Allen Set 1.5mm-10mm
½” Impact & Sockets Sm. Metric Socket Set Assorted Drill Bits Floor Jack or Equiv.
Sm. To Med. Bottle Jack Forklift or O/H Crane Hand Held Grinder Paint Gun
Pry Bar 3/8 Drill Motor Heat Gun or Equiv.
Min. 250 Amp Welder Cutting Torch or Equiv.
1 Im
R
1
1)
2)
3)
4)
5)
mportant No
Revision 1.0
Im1. Read M
2. Mount f
3. Refer to
4. Pay spe
5. All weld
6. For flip
7. For swi
8. A
9. Contac
10. D
over sp
11. Verify th
12. Grease
13. Verify th
decals)
14. F
future r
15. Refer to
BED HEIG
Measu measu
MOUNT TU
Measur
MOUNT TU
Measur
REAR SILL
Refer to
GROUND
Measur
otes:
0
mportant NManual com
fixture must
o your truck
ecial attentio
ding should b
up door or f
ng door app
Always Grou
t PALFINGE
Do not paint
pray)
hat pin lock
e all pivot po
hat ALL dec
Final Check-
eference.
o owner’s m
HT [H] Bed
re from topred.
UBE HEIGH
re from TOP
UBE [K]
re from rear
L CUT OUT
o H, K &S C
CLEARANC
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Notes: mpletely befo
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manufacture
on to items m
be performe
full seal kit a
plications, ple
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ER Liftgates
cylinder sha
bolts are tig
ints
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Off-Sheet at
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(Refe
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HT [F]
P of Mount T
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T [S]
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ore beginni
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marked with
ed by qualifie
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Importaner to line dra
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forward edg
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ng any wor
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please read
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Installations
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nt Dimensawing on follo
=Unloaded
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ALFINGER L
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owing pages
K-18 INSTAL
auxiliary equ
standards
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d in this Insta
nated brake c
Liftgates to r
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s
LLATION MA
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ANUAL
- 4 -
s
nual
emove
missing
cords for
en
1 Important Notes: ILK-18 INSTALLATION MANUAL
Revision 1.0 - 5 -
Mounting Notes:
Read and clearly understand manual BEFORE beginning ANY work
Important!!!
The basic rule of PALFINGER Liftgates’ ILK 18 installation is to raise mount frame
to achieve MAXIMUM ground clearance WITHOUT exceeding Min “F” dimension.
Refer to mounting tables and determine the proper [S] dimension. If the sill is greater than what’s allowed, the sill has to be notched and capped to achieve original strength. Bend flat stock and weld 100% around the notch.
Warning Minimum bed height dimensions are ALWAYS MAXIMUM LOADED TRUCK Floor Height Ranges: Max=Unloaded Truck; Min=Loaded
Installing a gate at or close to minimum bed height normally results in a gate that will NOT open and close from stored position if the minimum floor height is exceeded when truck is loaded.
Call tech support before starting the installation if you have any questions or concerns on mounting dimensions 888-774-5844
2 D
MA
R
2
Please fax inform
ation to Interlift (562) 9248318
Dimension Sh
ANUAL
Revision 1.0
Di
E
Please
faxinform
ationto
Interlift(562)924-8318
heet
0
mension
AC
F
DB
Sheet
D
Type of rear door: Roll-up .... S
wing .... F
lip-up...
B
C= R
ear sill height...........D
= C
rossmem
ber height...........E
= T
ire to end of body..........F
= B
ogie to end of body..........
Liftgate Type:...............Type of B
ody: Van.... Flatbed.... Refer.....
Make.................G
VW
R...............
Typeofrear
door:Rollup
Sw
ingF
lipup Trailer
E
A= B
edheight...........B
= Top of floor to bottom
of frame.........
Com
pany:.............................
Make
GV
WR
Phone.................... Fax.................... E
-mail..........................................
Til
ILK
FD
GB
ATrailer
K-18 INSTAL
Truck
Trailer
LLATION MA
D= S
pring hanger to end of body...........E
= T
ire to end of body..........F
= G
as tank to end of body (if applicable)..........G
= B
ottom of fram
e to bottom of gas tank........
CTruck
ANUAL
- 6 -
A= B
edheight...........B
= Top of floor to bottom
of frame.........
C= R
ear sill height...........D
=S
pringhanger
toend
ofbody
Fill out and send to Interlift if specific Install drawing is needed
Chassis D
imension S
heetFill
td
dt
It
liftififi
It
lldi
id
d
2 Dimension Sheet ILK-18 INSTALLATION MANUAL
MANUAL
Revision 1.0 - 7 -
2.1 Installation Dimensions ILK 18
IMPORTANT:
Always use the smallest F-dim possible for best ground clearance (don’t exceed max. ground clearance!)
K-Min 23.5" (at max F)K-Max 29" (at min F)
F-M
in 1
7.5"
F-M
ax 2
3.5"
Rear sill notchingNo Cut out required on 4.375" body rear sill height or less
cut out widths* without platform rollers - ** with platform rollers
* 7"**11"
* 7"**11"
44.5"
S
Max ground clearance 19.5" (never exceed max)Min ground clearance 14"Ground clearance = bedheight-F-3"
Min
bed
hei
ght 3
4"M
ax b
ed h
eigh
t 42"
3"
Figure 1 ILK 18 680 mm arm mounting dimensions
Figure 1 ILK 18 mounting dimensions
Part number for ILK 18 Mounting Fixture: 1-00015
MINIMUM bed height is defined as truck/trailer loaded to MAX GVW
3
R
3
3.1
R
1/2
Chassis and
Revision 1.0
Ch
Fli
1. Install ½”
Rear Lower Body S
2" x 1-1/2" HR Flat
d Body Prep
0
hassis an
p-Up door
” x 1-1/2” HR
Sill
aration
nd Body P
& Full-doo
R flat bar to t
TI
Preparati
or seal kit
the lower rea
Figure 2 F
RE
on for sp
installation
ar body seal
Full door seal ki
G
ILK
pecial app
n
l
it
Gasket Cha
Gasket Chan
K-18 INSTAL
plications
annel
nnel (Full Do
LLATION MA
s
oor Kit Only)
ANUAL
- 8 -
TIRE
3 Chassis and Body Preparation ILK-18 INSTALLATION MANUAL
Revision 1.0 - 9 -
6"
Off-set approx. 1" to the rear
Set distance so gas strut is fully extended when door is open
Rubber Hinge Seal
Approx 2"
Face Piston indown position
2. Install gate per instructions per 4.1
3. Install gasket channels on rear vertical body posts to match width of platform
4. For full door seal kits install gasket channel along header at edge of platform
Figure 3 Flip-Up door
5. Apply Silaprene (or equivalent) to gasket channel and slide gasket into channel
6. Trim gasket flush with channel and crimp channel slightly at top and bottom to lock gasket
7. Install flip-up door
8. Verify Hinge Seal is approximately 3/16” above top hinge and even before tightening any fasteners
Open door several times before tightening any top hinge fasteners
9. Install lower gas strut mount so that gas strut is fully extended when door is open
10. Lower gas strut mount should be off set (approx. 1”) to the rear of body to pull door in when closed
Flip-Up door
Platform tip
Rear body post
3 Chassis and Body Preparation ILK-18 INSTALLATION MANUAL
Revision 1.0 - 10 -
3.2 Swing door applications
A bridge kit is recommended for the usage of an ILK 18 liftgate behind swing doors. Due to the shifted pivot points all welding and cut out points have to be shifted accordingly.
3" Channel (Bridge Kit)
Notch Channel To Clear Door Latch Hardware
Top View
Side View
Full Weld (Weld to Arm ONLY)
Bridge Kit Detail
1/2"x2" HR Flat
3"x4.1 Channel
When using 3" channel bridgeinstall liftgate so platform is 3-1/2" to 3-3/4" from door gasketwhen door is closed
CL
Figure 4 Bridge kit for swing door application
Please consider your particular door frame. Set up for best solution for your application.
4
Re
4
4.1
4.2
Gate and Pl
evision 1.0
Ga
Refer to
Refer to
Sil
1. Notch r2. Box in n
2 Ins
1. Locate
2. Attach t(The mcan be
3. Tie tilt c
4. Slide m
you shominimuposition
S
atform Insta
ate and P
o 3.1 for flip-
o 4.2 for inst
l Preparati
rear sill if necnotch with fla
stallation w
and mark ou
the PALFINGounting fixtuused over a
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mount tube uould place thums in mindn the mount
SIDEVIEW
allation
Platform I
-up door/fu
talls with M
ion
cessary per at bar to ma
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ut the center
GER Liftgateure must be oand over) h rope or wi
F
nder the truche mount tubd (K- and F-tube. Make
Figur
Attach
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ll seal kit an
ounting Fix
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ting fixture
r of the rear
es mountingordered sep
re to lift arm
Figure 5 : Moun
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xture BEFO
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RE INSTAL
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liftarm to thed position, keuse a forklifte tube at a 9
with fixture
KVIEW
K-18 INSTAL
ations BEFO
LLATION
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Always mpursuit th
MAXIMUMCLEA
LLATION MA
ORE INSTAL
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make sure to he policy of
M GROUND
ARANCE
ANUAL
- 11 -
LLATION
place. hased it
his point mums and r device to truck bed.
D
4 Gate and Platform Installation ILK-18 INSTALLATION MANUAL
Revision 1.0 - 12 -
5. With the mount tube held in place, position the mount plates over tube and against truck frame. As
most Truck makers require chassis specific mount plates make sure you have specified the truck make and body lengths you are mounting on as well as using the correct mount plates and chassis holes for the installation
14 mm fasteners need to be torqued to 140 foot/lbs
MB Sprinter - Mount plates 08-531.65-00.00-00 Ford Transit - Mount plates 08-531.69-00.00-000
Figure 7.2 Mount frame with MB and Ford Mount plates
Before tightening down the mount plates to final position, check that liftgate is balanced and not binding in mounting fixture, you should have equal pressure on each lift-arm pin. This is very important to make platform align with truck sill.
Cover power pack before any welding. IMPORTANT!!!!!!
6. The reservoir is made of plastic and you will burn it while welding. Make sure hoses and cables are covered if you need to do any welding for the installation of mount plates
Figure 8 Cover power pack
7. The ILK 18 was especially designed for the wide frame Panel Van Chassis, all these chassis has
pre-determined hole patterns for installation of the mount plates
Before finishing the install we recommend doing the electrical installation (see 5, Page 21) and platform installation (see 4.3, Page 13) to make sure that everything aligns like it should.
4 Gate and Platform Installation ILK-18 INSTALLATION MANUAL
Revision 1.0 - 13 -
Figure 9 Bolted mount plates (picture shows Ford Transit)
Before running the unit through its cycle, make sure that the In-Cab Switch is in the “ON” position (lights on) Before running the unit through its cycle, make sure that the solenoids on the lift cylinders are not hitting the mount plates or Chassis items
4.3 Platform Installation
If power pack is still removed from mount tube for welding, reconnect the ground cable and pow-
er connection. Do not push back in, welding is not finished!!!!!!
Attention: check all PC-Board connections for tightness
4.3.1 Attach platform to liftarm
1. Remove pins attached to mounting fixture and lift arm. Lift arm will drop about 12”- 16”.
2. Remove mounting fixture from truck bed
3. Lower lift arm to ground to bleed air out
4. Support platform horizontally with forklift, overhead crane or similar equipment
5. Install platform onto lift arm using small pins.
6. Tighten up pin lock bolts
4 Gate and Platform Installation ILK-18 INSTALLATION MANUAL
Revision 1.0 - 14 -
4.3.2 Installation and Adjusting the tilt cylinders
Pin only one cylinder at a time to the platform
Figure 10 Attaching of platform with tilt cylinders
1. Tilt platform up to a point of easy access of the tilt bushings (using the forklift, overhead crane, etc.)
2. When installing the tilt cylinder into the platform, extend the tilting cylinder by pressing the switch for opening and closing until the pins fit in the tilt cylinder and the platform bushings. For this purpose, hold the platform sensor B-16 with the cable straight down.
3. For the platform to be in the required end position, the tilting cylinder must be fully extended
4. Verify that reservoir breather cap is installed and hydraulic fluid is at proper level with platform on the ground
Make sure to tighten the tilt piston rod lock nuts when you are finished.
Wrench Sizes for Tilt Cylinder Adjustments
Gate Model Nut Piston ILK 18 29MM 29MM
How to adjust the tilt cylinders:
1. Raise the gate all the way up against the truck body.
2. Close the platform – tilt cylinders fully extended.
3. Look for a gap at the platform tip and the body.
4. If platform is not completely in a vertical position, open up platform about 15-20 degrees and lower down about 5”-10”. Adjust the tilt cylinders by rotating the piston in the cylinder head.
5. Repeat step 4 till platform is vertical and even with body
6. Tighten left and right lock nut at tilt piston to keep
Ideal position: 45 degrees
4 Gate and Platform Installation ILK-18 INSTALLATION MANUAL
Revision 1.0 - 15 -
Round side of tilt cylinder clevis MUST face down towards ground
Lock nut to be tightened when platform is in vertical positionRound shape of clevis towards the ground
If you have not finished the welding, carefully run lift to see if it is properly aligned with the floor sill, remove pump & motor from tube and finish all welding work before continuing with detail work.
Never power the lift hard against anything if you have not finished welding.
4 Gate and Platform Installation ILK-18 INSTALLATION MANUAL
Revision 1.0 - 16 -
4.4 Installation without mount fixture
1. Connect platform to lift arms using short pins
2. Tie tilt cylinders with rope or wire to lift arm to avoid dragging on the ground
3. Support platform with forklift, overhead crane or similar device
4. Lift platform up and support mount tube with rolling floor jack or similar device
5. Slide platform/mount tube assembly under the vehicle frame
6. Set platform so it is centered level and flush with body floor
7. Secure and attach platform to body using 3” channel or equivalent with tack welds (steel platform) or clamps (aluminum platform) to assure level position of platform to body floor (shown in Figure 4.3)
Warning: Never work or place yourself under unsupported Platform
8. Place the mount tube in the predetermined position, keeping the given maximum and minimum F- and K-Dimensions in mind. Use floor jack or a similar device to position the mount tube. Make sure that you place the tube at a 90-degree angle to the truck bed.
Figure 4.11: Platform install without fixture
9. When mount frame is in place, tack weld mount plates to mount tube with minimum three 2” welds and three 2” welds to the frame.
10. Before finishing all welding we recommend doing the electrical installation (see chapter 5 on page 21) and to make sure that everything aligns like it supposed to be.
11. Remove the 3” channel and follow instructions to install tilt cylinder as shown in chapter 4.3.2
Install gate at maximum ground clearance.
4 Gate and Platform Installation ILK-18 INSTALLATION MANUAL
Revision 1.0 - 17 -
4.5 Setting and Operation of B-16 Sensor
1. Mount the platform sensor B-15 to the right-hand side of the platform as shown in Fig.4.4. Make sure to loop wire around to give it enough slack in normal operation and route clear of any pinch points.
2. Close the platform as much as possible to body of vehicle. (Tilting cylinder is fully extended). Relieve tilting cylinder pressure with the ‘tilt open’ switch. Adjust the platform to required vertical po-sition by turning the piston rod in or out of the clevis using a wrench (See page 14). Repeat the set-ting procedure if necessary. It is important that both of the cylinders are adjusted equally.
3. Verify that the platform sensor B-15 is set correctly by placing platform in stored position (fully verti-cal) and check that warning lights are off (with cab switch off). If lights still on when gate is stored, loosen the 5mm x 50mm Allen Head mount screws at sensor and rotate slightly till lights turn off. Re-tighten screws
Figure 4.12: B-16 Sensor and warning light cable installation and placement
Warning Light/Foot Control (option) MUST have all connectors tied off and inserted into platform profile after connections are made. Route cables secure to avoid damaging harness during regular operation
Assure that B-15 sensor is installed with a service loop so cable does not get damaged during full cycle of platform. With platform in vertical position the wire is point-ing straight down, parallel to the platform surface.
4 Gate and Platform Installation ILK-18 INSTALLATION MANUAL
Revision 1.0 - 18 -
4.6 Setting and Operation of B-13 Sensor
1. Raise platform approx. 8” – 10” off ground and verify platform is level (tilt if necessary)
2. Loosen lock bolt and set sensor level with platform surface/ground (verify colored side of sensor is out, plastic housing is facing to lift arm)
3. Lower platform to ground. When properly set, platform should remain level for approx. 2 seconds, then tip will tilt towards ground.
4. Cycle Platform from bed height to ground several times to verify proper operation. Tilt sensor slightly forward or back to achieve proper Auto-Tilt action.
Lift Arm
Lift Cylinder
B-13 Sensor
Tilt Cylinder
At NO time should the platform tilt towards ground while lowering. Platform should ONLY tilt AFTER Lift Arms/Nylon Rollers contact ground.
5. After sensor is properly set, tighten lock bolt to 43 in.lbs/3.5 ft.lbs
6. Cycle platform several times to check operation after tightening.
7. If Platform does not level, but lifts up only, check batteries, start truck in fast idle.
8. Fold down Lock Tab tightly onto Lift Arm (see above)
Never over torque B-13 lock bolt.
Verify colored side of sensor is out (facing away from arm)
Under torqueing B-13 lock bolt may allow sensor to shift during normal gate operation.
8"-10"
Sensor horizontal in this position
B-13
4 Gate and Platform Installation ILK-18 INSTALLATION MANUAL
Revision 1.0 - 19 -
4.7 Installation of left and right Up Stops
Weld to C/M's
Weld to Stringer
Suggested Stop #2
Suggested Stop #1
Damage to the body may occur if up stops are not installed properly
How to install the Up-stop:
1. Raise platform up to rear sill verifying it is level with body floor and there is a slight gap (appr. 1/8”) between lift arm and rear sill.
2. Determine type of up stop for your installation. 3. Set up stop so that it makes contact with liftarm. 4. Tack weld in place. 5. Cycle gate to verify liftarm makes contact with left and right up stops before making contact with rear
sill. 6. There is not an excess gap between rear sill and liftarm 7. Platform is level with body floor.
Install the liftarm up stop so it is positioned in a way that it stops the liftarm when the platform is level with the floor of the truck
4 Gate and Platform Installation ILK-18 INSTALLATION MANUAL
Revision 1.0 - 20 -
4.8 Finalize Install
If any welding is required for sub frame or mount plates Protect all wires from dropping slag or splatter when welding mount plates.
1. Verify the platform is in the correct position in relation to truck sill.
2. If a bolt on installation is not possible due to different chassis set up-Weld mount plates to chassis/ body subframe with a min of 2 x 12” x 1/4” fillet weld around mount plates and chassis/body long sill
3. PALFINGER Liftgates recommends adding 3/16” flat bar or plate to the top of mount plates if need-ed to tie Liftgate mount plates to body stringer.
5
Re
5Whis n
5.1
Electrical Ins
evision 1.0
Elehen performinot subject to
Never e and mo
Ma
1. Install t2. Secure 3. Heat sh4. Assure
MainBatte
stallation
ectrical Ining electricao damage fr
exceed ratinotor
ain Power C
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hrink lug conall connecti
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+
+
CircuitBreaker
nstallatioal installationrom moving
ng of existin
Connectio
ttery cable svery 12 inch
nnection to cons are tigh
(Third Batfor heavy
-
-
Control PTruck AppTrailer Ap
on n, please be parts, sharp
ng fuses loc
ns
securely fromhes. cable. t and secure
ttery Showny applications O
L
To Ignition Switch
Gro
Aux. Bat(if applic
BatteryIsolator
(if applica
Power 4-Wireplication-Alwaypplication-wire
certain to inp edges, exh
cated at the
m mount fram
ely fastened
Only)
-
Liftgate M
Ground
-
n
ound
tteries cable)
yr
able)
-
e Cableys wire to tructo aux. battery
In-Fu
ILK
nstall and sehaust system
e battery an
me to battery
.
+-
Mount F
+-
+-
k batteryy
-Lineuse on #2 and #27
K-18 INSTAL
ecure everytms, etc.
nd control b
y.
Frame
2G
aLi
ftgat
eP
ower
Cab
le
CircuitBreaker
LLATION MA
thing in a w
board at the
Gro
und
Cab
le
Groun
2 G
a. L
iftga
te P
ower
Cab
le
Motorsuppl
Contpow
ANUAL
- 21 -
way where it
e pump
nd
r power ly
trol board wer supply
5 Electrical Installation ILK-18 INSTALLATION MANUAL
Revision 1.0 - 22 -
FOLLOW DOTTED LINE IF ISOLATOR OR AUXILLIARY BATTERIES INSTALLED!
Never secure cable in a way where it can make contact with other wiring, brake fuel or airlines etc or get pinched against other objects. Never run wiring next to fuel hoses or attach to it.
Breaker Installation (Fig. 5.1)
1. Mount circuit breaker securely in battery box 2. Connect liftgate 2Ga. cable to open stud on circuit breaker 3. Connect 2Ga. jumper from forward most stud on breaker to positive battery post
Figure 5.1: Circuit Breaker installation
Mount circuit breaker securely in battery box or at positive battery post using supplied buss bar Connect liftgate 2Ga. cable to open stud on circuit breaker Connect 2Ga. jumper from open stud on breaker to positive battery post if circuit breaker was not
mounted straight at battery with buss bar
1. Determine location for fixed control box; locate it in a way that the operator can view the platform and surrounding areas while operating the liftgate. Also, locate in a way where the lid does not ex-tend outside the van body when open.
150 AMP Resetable Breaker
RESET
Connect 2 Ga cable coming from lift gate
Connect here to Positive Battery post
Suggested mounting dimensions
5 Electrical Installation ILK-18 INSTALLATION MANUAL
Revision 1.0 - 23 -
5.2 On-off switch installation
Install the cab shut-off switch inside the cab. Locate it where it can conveniently be seen and reached from the driver’s seat as well as from the ground.
Place cab shut off in view of the driver and within reach from the ground.
Recommended Cable Routing for Trucks
Body Stringer
Sub Wood
Truck Frame
Cable Staples
Route Cables to OUTSIDE of U-Bolts
For trailer installation refer to trailermanufacturers recommended routing
Battery Cable
2 Wire Control Box Power Cable
4-Wire Control Cable
2. Lead the 4-wire cab switch together with the battery cable and the 4 wires for the control power to
the batteries along the sub-wood. Secure the cable every 12 inches against the sub-wood with cable staples. Run only the cab switch into the cab. Battery cable and 4 wire control power cable will go directly to the truck battery. (#2 and #4 go to positive post with an inline 20 amp fuse; #1 and green/yellow go to negative post)
In-Cab Cut-Off Switch (For Truck Use Only)
Green/Yellow (-)
White (#1)
Blue (BS3)
Red (#2)
Blue (#4)
"Off" Symbol
In-Cab Switch Color and Number Coding
Cable wires are marked: Cab Cut off Switch Code 1 = Hot Lead To Red L.E.D. Lights - WHITE (-) = Ground To L.E.D. Lights - GREEN YELLOW 2 = 12 Volt Power - RED 4 = Control Power To Liftgate - BLUE
5 Electrical Installation ILK-18 INSTALLATION MANUAL
Revision 1.0 - 24 -
5 Electrical Installation ILK-18 INSTALLATION MANUAL
Revision 1.0 - 25 -
Inspect and test all electrical connections, wiring and the different functions to make sure that the electrical installation is complete.
5.3 Remote Hand Control Installation
Hand Controls are NOT weatherproof and have to be stored inside body in holster or in weatherproof box (PALFINGER Liftgates option). For “Refer”- & Flatbed Installations or stored in cab solutions we recommend “plug & socket” option.
1
2
Hand Control Holster
Mount Holster inside body on curb side at rearMount approx. 40"-48" from floor (end user needs may very)
BUTTON NO. 1 – UP BUTTON NO. 2 + 1 – TILT CLOSE BUTTON NO. 2 – TILT FUNCTION ACTIVATION BUTTON NO. 2 + 3 – TILT OPEN BUTTON NO. 3 – DOWN
Connect all wires together according to cable ID’s. Use heat-shrink to seal the connection.
3 Button Hand Control
Function From H/C / Color From Gate / Number
Up - 5.2 / Yellow 5.2 - #4
Down - 6.2 / Brown 6.2 - #3
12V Hot - 4.3 / Red 4 – Gn/Ye
Tilt-Up - 3.2 / White 3.2 - #1
Tilt-Down - 14.2 / Green 14.2 - #2
3
5 Electrical Installation ILK-18 INSTALLATION MANUAL
Revision 1.0 - 26 -
Optional Plug and Socket application
3 Button Hand Control
#4
#2
#1
Female Receptical (Looking at Front)
#3
Green/Yellow
Figure 5.2: Plug& Socket wiring for Hand Control
5 Electrical Installation ILK-18 INSTALLATION MANUAL
Revision 1.0 - 27 -
5.4 Wiring Diagrams
war
ning
lig
ht
O
PTI
ON
AL
WA
RN
ING
LIG
HT
S &
FO
OT
CO
NT
RO
LS
150
Flu
sh 3
But
ton
Con
trol
WIR
LES
S H
AN
DC
ON
TR
OL
OP
TIO
NA
L
CIR
CU
IT B
OA
RD
2 G
A C
AB
LE
4 W
IRE
CA
BLE
Lege
nd :
gn :
gree
nbl
: bl
uebr
: br
own
wt :
whi
teye
: ye
llow
bk :
blac
kgy
: gr
een-
yello
w
# 2
BLA
CK
# 4
BLA
CK
# 1
BLA
CK
GR
EE
N /
YE
LLO
W
(+) (-
)
LI :
Lift
Up
LO :
Low
er D
own
OP
: O
pen
Gat
eC
L :
Clo
se G
ate
ILQ
K
1PLU
SH
AC
KB
AR
TH
159
39 P
ium
a A
ve
Cer
ritos
, CA
907
03
Figure 5.3: Electrical schematics
5 Electrical Installation ILK-18 INSTALLATION MANUAL
Revision 1.0 - 28 -
5.5 Connector Overview
CIR
CU
IT B
OA
RD
PO
WE
R P
AC
K
B-1
3 LI
FT
AR
MB
-16
PLA
TF
OR
M
GR
OU
ND
CO
NT
RO
L PA
NE
LC
AB
CU
T O
FF S
WIT
CH
FOO
T C
ON
TRO
LW
AR
NIN
G
LIG
HT
S
HA
ND
RE
MO
TE
CY
LIN
DE
RS
LIF
T 15
(2
ea)
TIL
T 14
(2ea
)
Figure 5.4: Electrical Wiring overview
5 Electrical Installation ILK-18 INSTALLATION MANUAL
Revision 1.0 - 29 -
5.6 Hydraulic Schematic
Functions:
Lift: MLower: S1+S2+S5Tilt Up: M+S5Tilt Down: S3+S4Horiz. Open: M+S3+S4
Pressure Relief
2850 PSI200 bar
Shift Valve S5
Restrictor Valve R5
Flow Divider
Functions:
S1 and S2 = Release Valve for lowering functionS3 and S4 = Release Valve for tilt down functionR1 and R2 = Flow Restrictor located inside hose adaptor on lift cylinderR3 and R4 = Flow Restrictor located inside hose adaptor on tilt cylinderS5 = Shift Valve is activated on tilt up and lowering functionR5 = Restrictor Valve located in power packFlow Divider is activated, when fluid is going back into the power packIf Flow Divider is loose or hanging up the fluid is circulated back in to tank
Figure 5.7: Hydraulic schematic
6
Re
6
Lubrication a
evision 1.0
Lu
1. Open p
2. Remov
3. Lower
4. Cycle p
5. Wipe e
6. Check
7. Paint a
N
8. Remo
9. Check
10. Re-rou
11. Lower
12. Check
13. Install
T
and Final Ins
ubrication
platform an
ve red caps
platform to
platform op
excess grea
k ALL pin lo
all welded a
Note: Do n
ve any ove
for any wir
ute and/or ti
platform co
Plugs on P
all operatio
TIRE
2
4
spection
n and Fin
d lift gate to
s, apply gre
ground an
pen and clos
ase from joi
ock bolts f
areas and a
not paint ch
erspray from
res or hoses
ie up wires
ompletely to
PC Board. P
on and safe
Figure 6.1: L
al Inspec
o bed level
ase until gr
d grease le
sed severa
ints and rep
for proper
area that ha
hrome hyd
m cylinder p
s that may
and hoses
o ground an
Push tight a
ty decals
1
3
5
6
Lubrication Poi
ction
rease begin
eft over grea
al times and
place ALL r
torque of 1
ave been sc
draulic pist
piston rods
rub during
as necess
nd slide out
and reinstal
ints (opposite d
ILK
ns to flow fr
ase zerks.
d grease ag
red caps
14 ft-lbs
cratched du
ton rods
operation.
ary
t pump/mot
ll clamp on
direction on cur
K-18 INSTAL
rom bushing
gain (Fig. 6.
uring installa
tor to check
rubber cov
rb side)
LLATION MA
g ends
.1)
ation
k oil level
ver
TIRE
ANUAL
- 30 -
6
Re
6.1
Fo
sid
sur
(A)
(B)
(C)
(D)
(E)
(F)
(G)
(H)
(J)
(K)
Lubrication a
evision 1.0
De
r operator’s
de of liftgate
re to place
) 1 ATG-URG
) 1 ATG-ILK
) 2 ATG-XXX
) 1 ATG-CAB
) 1 ATG-BKR
2 ATG-WLH
) 2 ATG-CTN
) 1 ATG-RES
1 ATG-OP
) 1 ATG-FT -
Deca
Deca
Decal -
and Final Ins
ecal Placem
s safety, all
e. This is ty
the maximu
GWA - Urge
- Main Ope
XX - Max. Ca
B - Liftgate S
R - Circuit Br
H - Warning
N - Caution:
SET - Circui
ENILD - Not
- Notice for F
al - A
al - H
E
spection
ment and In
decals app
pically a co
um capacit
ent warning:
eration (Cont
apacity (plea
Shut-Off (mu
reaker Rese
: liftgate can
Always stan
t Breaker Pr
tice for Open
Foot Control
nspection
pearing in “
ombination
y decal (D)
Elevating ga
trol Box)
ase check th
ust be placed
et (must be lo
n crush
nd clear of p
rotection
n & Close
l (if applicab
Decal - B
Dec
Dec
“Decal Kit”
of decals o
) on driver a
ate instructio
he serial num
d next to the
ocated at the
platform area
le)
al - F
al - J
ILK
must be in
on the liftga
and curb sid
ons
mber plate to
e Shut-Off Sw
e circuit brea
a
Decal
K-18 INSTAL
a conspicu
te and truc
de.
o find out yo
witch)
aker)
- C
LLATION MA
uous place
ck body. Ple
our specific c
Decal
Decal - G
Decal - K
ANUAL
- 31 -
on control
ease make
capacity)
- D
6
Re
Lubrication a
evision 1.0
Deca
of the
from
platfo
and Final Ins
al G (on the
e platform; v
outside
orm is closed
spection
back
visible
when
d)
Figu
ure 1: Deca
Deca
Deca
al Placemen
ILK
al C
al F
nt Guideline
K-18 INSTAL
e
D
O
D
at
A
fo
3”
LLATION MA
Decal A
Decal B
Decal H
Decal J
Decal K
Decal D - in t
On - Off at re
Decal E - by
t batteries
Aluminum o
or foot contro
”x4”, P-1341
ANUAL
- 32 -
the cabine o
ar
circuit brea
operation p
ol
1966
r at
aker
late
6 Lubrication and Final Inspection ILK-18 INSTALLATION MANUAL
Revision 1.0 - 33 -
"B"
2-3/4"
"C"
1/4"
"D"
5-1/4"
Palfinger Liftgates LLC15939 P
iuma A
ve.C
erritos, California 90703
may not be traced, copied or used
without the w
rittenperm
ission of Palfinger
This drawing and it's contents are
the the property of Palfinger
and
Draw
n by:D
ate:R
ev Date:
MH
4/05/15Liftgate M
ounting Fixture
56"
Model
"A"
"B"
ILK 18/22
ILK 33
ILK 44/55
"C"
"D"
44-3/4"
53-1/4"
53"1-1/2"
1-3/8"
1"15/16"
1-1/4"
1-7/16"
Correct P
lacement
ILQ 22-ILK
18/22/33/44/55/66
"A"
Inside Dim
ension
3"x3"x1/4" Angle
7/8"
1-1/4"
1-5/16"
ILK 66
ILQ 22
44-3/4"1"
15/16"
7
Re
7
Check Off S
evision 1.0
JOB NO.
GATE NO.
OWNER'S M
ON-OFF SW
WIRING
HYD. LINES
SECURED
HYD. OIL
LEAKS
WELDS
PUMP
& MOTOR
PINS
Note:This mustpresented
Ch
Sheet
MANUAL IN CAB
WITCH WORKING
1. Power Co
2. Cables No
3. 12V Contr
4. Loomed &
5. Circuit Bre
Installed &6. Loop in pl
1. No Rubbin
2. No Rubbin
3. Up-Down
4. Storing Pl
1. None At H
2. None Pow
3. Cylinders
1. Full Welds
2. Ground Of
3. Frame Ca
1. Check Flu
2. Connectio
3. Power Ca
4. Ground Ca
5. Breather I
6. Cables Tie
7. Fuses Tig
8. Clamp on
1. Grease Ze
2. Red Greas
3. Bolts Tigh4. Ground Ro
t be filled out ad to PALFINGE
heck Off S
& DECAL IN PLA
rd Secured
ot Rubbing Steel
rol Wire Secured
& Stapled
eaker & Fuse
& Decal In Placeatform sensor wire
ng On Frame
ng On Platform
Clear
atform Clear
Hoses
wer Pack
s Mount Plates
ff / Clean
apped Off
uid With Platform
ons Tight With Hea
ble Tight
able Tight
nstalled
ed Off
ht
cover
erks In Place
se Caps On Zerks
ht On Pinsollers On
and kept for yER Liftgates f
Sheet
ACE
OPER
re
FINAL
INSPE
On Ground
at Shrink
OPTIO
CHEC
s
your records. for any warran
VIN NO.
RATION 1.
o
2.
3.
4.
A5.
w6.
7.
a
8.
9.
L 1.
ECTION 2.
3.
4.
5.
6.
7.
8.
9.
10
11
ONS 1.
2.
3.
CKED BY
DATE
A copy of thisnty compensa
ILK
All Functions Op
outside Control &
Up Stops In Plac
Platform Meets B
Sensor Set For P
Auto tiltWarning lights st
when platform stoCab switch not fla
platform stored an
Platform hits rear
at the same time
Titl cylinder clevis
lock nuts tight
No Paint on cylin
Platform Touches
Lights Working O
Lic. Plate Bolts &
Decals Installed
Rubber & Plastic
Gate Painted Com
Body Clean Arou
Pin Greased - 12
Cylinders Clean
0. Clamp on cover
. Exhaust mud fla
All Options On G
Circuit Breaker T
Cart Stops Work
s sheet must ation
K-18 INSTAL
erate On
Hand Control
ce
Body
Proper
top flashing
oredashing when
nd switch off
r sill even
s
nder shafts
s Ground
On Chassis
& Lights
c Caps on
mpletely
und Gate
2 Places
aps are ok
Gate
Tight
ing
be
LLATION MAANUAL
- 34 -
7
Re
8
8.1
Check Off S
evision 1.0
Ins
Me
Sheet
stallation
ercedes Be
995 mm
1960 mm
35 mm
L 1250 mm (1350)
rear chassis overhang L
230 mm
N min.0 (550)
N min.14 (680)
330 mm
n Referen
enz, Wheel
180 mm
max.621 mm
adjustable area
loaded 655 mm
295 mm
80 mm
0 mm
ce
base 144“
1240 mm pitch dimension
width of underrun protection device
3-part=2030 mm / 1-part=1960
1086 mm mounting plates inside
2
9
-170“
ILKK-18 INSTALLLATION MA
08
531
65
00
00
00
ANUAL
- 35 -
08-5
31_65-0
0_00-0
0
7 Check Off Sheet ILK-18 INSTALLATION MANUAL
Revision 1.0 - 36 -
8.2 Mercedes Benz, Wheelbase 144“-170“
L 1263 (1113) rear chassis overhang
N min.70/235(550)
N min.154(680)
max.415 mm(285)
adjustable area
100 mm
252 mm
loaded 602 mm
80 mm
240 mm
995 mm
35 mm
1959 mm
width of underrun protection device 3-part=2030 mm / 1-part=1960
1240 mm pitch dimension
1078 mm mounting plates inside
340 mm
08-5
31_67-0
0_00-0
0
160 mm
7 Check Off Sheet ILK-18 INSTALLATION MANUAL
Revision 1.0 - 37 -
8.3 Ford Transit, Wheelbase 123“-156“
width of underrun protection device
3-part=2030 mm / 1-part=1960
L 948 mm rear
chassis overhang
single wheel (L1-L3) 1935 mm
double wheel (L2-L3) 2047 mm
N min.344 (550)
N min.428 (680)
max.175 mm
adjustable area
128 mm
321 mm
loaded 661 mm
10 mm
250 mm
960 mm chassis / auxillary frame width
1240 mm pitch dimension
1078 mm mounting plates inside
262 mm
350 mm
99 mm
08-5
31_68-0
0_00-0
0
(122 mm)
7 Check Off Sheet ILK-18 INSTALLATION MANUAL
Revision 1.0 - 38 -
8.4 Ford Transit, Wheelbase 156“, Extended Chassis, 2014
single wheel (L4) 1935 mm
double wheel (L4) 2047 mm
960 mm chassis
auxillary frame width
350 mm
250 mm
103 mm
N min.0(550)
N min.45(680)
L 1332 mm (1502)
rear chassis overhang max.245
adjustable area
128 mm
321 mm
loaded 661 mm
100 mm
width of underrun protection device
3-part=2030 mm / 1-part=1960
1240 mm pitch dimension
1078 mm mounting plates inside
250 mm
1502
08-5
31_69-0
0_00-0
0
122 mm
7 Check Off Sheet ILK-18 INSTALLATION MANUAL
Revision 1.0 - 39 -