ILFP INSTALLATION MANUAL & CHECK-OFF SHEET ECN-M0258 Rev. 1.9, Date 07-15-2013 Part #90-1213-200 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.
TABLE OF CONTENTS TABLE OF CONTENTS TABLE OF CONTENTS ................................................................................................................................. 2 1 Safety Infromation .................................................................................................................... 5 2 Important Notes: ....................................................................................................................... 6 2.
TABLE OF CONTENTS 7 6.8 Control board wiring and connector setup (Easy move model)...................................... 31 6.9 Control board plug setup (Easy move model) ............................................................... 32 6.10 Easy Move Sensor Adjustment and setup ..................................................................... 33 6.11 Control box wiring (internal) for turn knob model ........................................................... 35 6.
TABLE OF CONTENTS Figure 27 Plug setup on PC - Board ......................................................................................................... 30 Figure 28 Electrical schematic Easy move ............................................................................................... 31 Figure 29 Plug setup on PC - Board ......................................................................................................... 32 Figure 30 Control box wiring schematic ...........................
TABLE OF CONTENTS 1 Safety Infromation This manual follows the Guidelines set forth in “ANSI Z535.4-2007” for alerting you to possible hazards and their potential severity. ! 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.
2 Important Notes: 1. Review lift gate invoice and packing slip to assure delivery of correct gate and complete delivery of accessories and optional equipment 2. Read Manual completely before beginning any work 3. Mount fixture may be ordered separately 4. Refer to your truck/trailer manufacturer’s instructions before adding any auxiliary equipment. 5. Pay Special attention to items marked with this symbol: 6. All welding must be performed by qualified personnel per AWS standards 7.
BED HEIGHT RANGE DEFINES THE LIMITS WITHIN THE LIFTGATE WILL OPERATE PROPERLEY. • Minimum bed height dimension is measured at MAXIMUM LOADED CONDITION • Maximum bed height dimension is measured at UNLOADED CONDITION, AIR BAGS INFLATED A gate installed on an unloaded vehicle that is at or near the minimum required bed height may be damaged by ground contact or may not operate properly when the vehicle is loaded.
3 Chassis Dimension Sheets Figure 1 Trailer dimension sheet Revision 1.
me Figure 2 Truck dimension sheet Revision 1.
4 Installation Dimensions - Installation Dimension sheets are supplied with each individual ILFP, as there are too many different setup combinations for a generic installation drawing. When ordering a liftgate, PALFINGER Liftgates supplies a drawing based upon the Chassis dimension sheet ( Figure 1 and Figure 2) supplied by installing company. IMPORTANT: Prior to beginning the installation review installation drawing supplied with your lift gate. It will be in the format of the example below (Fig.
4.1 Chassis and Body Preparation 4.1.1 Mount frame clearance The ILFP mount frame clearance will vary based on chassis/trailer bed height, lift gate platform size and lift arm length. (Refer to the specific installation drawing for mount frame requirement) - Determine the correct mounting clearance according to your specific lift and chassis. - With long overhangs it is even more important to maintain Max ground clearance.
4.1.2 Rear sill preparation To assure that the gate reaches the body/trailer floor, the rear sill of the truck/trailer may have to be cut. • If sill is 4“ or less No sill cut out needed • If no cut out height is determined in drawing, cut out for best fit. Keep at least a minimum of 4” of sill. • Reinforce every cut out of the sill to regain sill strength, required by truck/trailer OEM.
To avoid interference with the body, you may have to cut out the back sill. Figure 6 Sill cut-out – sideview • Reinforce all rear sill cut-outs to maintain sill integrity. • Some trailers are equipped with flat-bar reinforcements around the tail lights (eyebrows). In some cases these reinforcements will have to be trimmed or notched to allow the platform to reach bed level.
5 Gate Installation 5.1 Truck Installation Never work under mount frame or platform without safety supports 5.1.1 Slide rail and Push–Pull mount bracket installation 48" Slide rail(1 each side) Push-pull bracket Figure 7 Slide rail and push-pull installation BODY LONG RAIL 1/4" STEEL FILLER WOOD FILLER ILFP MOUNT BRACKET 1/4" STEEL BACKING PLATE TRUCK FRAME Figure 8 Mount bracket installation details Revision 1.
5.1.1.1 Installation without slide rail mounting fixture Make sure the specific install drawing supplied with the lift gate matches the truck and gate to be installed 1) Locate the 8 mount brackets on the chassis as indicated by the installation drawing. The brackets must be square to and level with the floor of the body at the precise height indicated on the installation drawing. Each mount bracket requires a minimum of 8” of ¼” weld.
5.1.1.2 Installation with slide rail mounting fixture 14.29" 1.50" 3.00" 3.00" 4.00" 14.39" 12.10" 2.95" 10.29" 0.68" 1.45" 1.49" 3.00" 3.00" 14.29" Figure 9 ILFP slide rail mounting fixture 1) Build two (2) mounting fixtures like shown in Figure 9. Use 3”x3”x.25” tubing. Assure that the holes are in EXACT location as otherwise the slide rails will be off and the gate might not work properly. 2) Slide the two 3” tubes into the slide rail and locate the correct position with the 3/8” stop bolts.
Liftgate attachment 5.1.2 700 48" Figure 9 Liftgate installation to previous installed rails 1) Weld the push pull bracket according to the drawing in between the frame channels. 2) Slide in lift gate assembly and connect pin in front of push-pull cylinder to bracket Revision 1.
5.2 Trailer Installation 5.2.
5.
5.4 Removal of transportation safety bolts When lift gate installed properly and basic functions available, transportation safety bolts have to be removed. Remove the bolts that are underneath the frame and attached to the bottom of the swing arms near to the end of lift cylinders. Remove bolts from both swing arms. Swing arm is able to swing when platform touches ground with bolts removed.
Control power wiring setup To maintain the best possible power supply, install the auxiliary batteries as close as possible to the gate. - Truck installations might not have an auxiliary battery kit (PALFINGER Liftgates always recommends a kit). In this case you have to run the control power straight off the truck battery.
5.4.1 Platform storage Up-stops With gate power wiring in place and fully functional, place gate and platform in final storage position for installation of up stops. - The up stop assembly (x2) and the steel right angle piece (x2) are included with every gate. Figure 15 Installation of up-stops - Up Stops MUST be installed to avoid damage to platform when travelling down the road - The up stop must be mounted high enough so that they do not make contact with the mainframe tube.
Slider rail stops setting 5.4.2 Holes for slider stop adjustment 700 Figure 17 Slider rail stops • For final adjustment, lift the platform all the way up till it is level with the truck/trailer floor • Choose the hole that is the closest to the mount plate in the slider rail • Install the bolt and tie it down in each side. • Use the same hole on each side to assure an even position of the platform with the body. Control box installation 5.4.
6 Electrical Installation When performing electrical installation, be certain to install and secure everything in a way where it is not subject to damage from moving parts, sharp edges, exhaust systems, etc. • Any deviation from PALFINGER Liftgates’s recommended power setup (see 6 Electrical Installation) will void warranty and product liability unless you have a written confirmation by PALFINGER Liftgates that allows you to do specific changes.
Wiring schematic main battery power - Truck setup 6.2 Liftgate Mount Frame Main Truck Batteries + - Ground Cable Circuit Breaker 2 Ga. Liftgate Power Cable Ground + To Ignition Switch Ground Battery Isolator (if applicable) Aux. Batteries (if applicable) (Third Battery Shown for heavy applications Only) - + - + - + Circuit Breaker Ground Figure 20 Main wiring - truck setup Revision 1.
6.3 Wiring schematic main battery power - Trailer setup 2 Ga. Liftgate Power Cable Dual pole plug Ground (Third Battery Shown for heavy applications Only) - + Aux. Batteries - + - + Ground Cable Liftgate Mount Frame Ground Figure 21 Main wiring - trailer setup - dual pole charging system Liftgate Mount Frame Ground (Third Battery Shown for heavy applications Only) - + Aux. Batteries - + - + Ground Cable 2 Ga.
6.4 Trail charger installation Trail Charger + + - 2 Ga. Liftgate Power Cable 7 way plug – white for tractor power Ground 7 way plug – aux pin for tractor ignition switch Aux. Batteries - + - + - + Ground Cable Liftgate Mount Frame Ground Ground Figure 23 Trail charger wiring • Install the 2 Ga. positive and negative battery cables securely from mount frame to battery and truck/trailer chassis with proper service loop for sliding liftgate.
6.5 On/off switch installation 6.5.1 Truck setup Lead the 3-wire cab switch (J-11 plug) together with the battery cable (2 Ga battery cable ) and the 4 wires for the control power (J1 #2 and #27; J2 #“-“)to the batteries along the sub-wood. Secure the cable every 12 inches against the sub-wood with cable staples. Run the cab switch only into the cab. Assure that the switch has the jumper from the blue to the white cable in place. (Responsible for the L.E.
Revision 1.9 5-11-2011 HACKBARTH (+) ILFP 35/40 2 GA CABLE KPLUS 4 WIRE CABLE (-) CIRCUIT BOARD Jumper # 1 BLACK GREEN / YELLOW # 2 BLACK # 4 BLACK gn : green bl : blue br : brown wt : white ye : yellow sw / bk : black gy : green-yellow Legend : OUT IN BL BR BR BL DOWN Black #6 POWER Black #4 UP Black #5 Optional: 6 down Optional Toggle control MBB part# 2004565 4 5 up Center Button Red 3 Button Control 6.
6.7 Control board plug setup FOOT CONTROL GROUND for PC BOARD CONTROL PANEL CAB ON-OFF SWITCH TRUCK SLIDE VALVES WIRELESS CONTROL CYLINDERS LIFT 15 (2 ea) POSITIVE for PC BOARD (black #2 to 2 and black # 4 to 27) STOP POWER PACK START JUMPER on Trailer PUSH-PULL CYLINDERS SECONDARY HARNESS for SLIDE function CIRCUIT BOARD K+ Figure 27 Plug setup on PC - Board This graphic describes the different functions of each plug and where it is connected to.
Revision 1.9 Wires: brown - 12V blue - 0V white - signal 5-11-2011 HACKBARTH Proximity Switch "E"-white wire: - 0V at stored position (metal contact) - 12V out of storage (no metal contact) (DO not use black wire) Restrictor 1 MOhm Program ver. 2.30 works in combination with the proximity sensor to control the warning lights (+) 2 GA CABLE (-) KPLUS 4 WIRE CABLE ILFP 35/40 br bl OUT IN Warning lights (optional) CIRCUIT BOARD Jumper Voltage difference between store and slide position 0.
6.9 Control board plug setup (Easy move model) GROUND for PC BOARD WARNING LIGHTS FOOT CONTROL CONTROL PANEL JUMPER SLIDE VALVES POWER PACK CYLINDERS LIFT 15 (2 ea) START POSITIVE for PC BOARD (black #2 to 2 and black # 4 to 27) STOP WIRELESS CONTROL Easy move Proximity Switch PUSH-PULL CYLINDERS SECONDARY HARNESS for SLIDE function CIRCUIT BOARD K+ Figure 29 Plug setup on PC - Board This graphic describes the different functions of each plug and where it is connected to.
6.10 Easy Move Sensor Adjustment and setup The PALFINGER Liftgates ILFP Easy Move is a self-adjusting sliding option. The Easy Move requires - (1) B-15 Sensor, mounted to the inside of the main lift arm - (1) Proximity switch, installed at the sliding mount plate - (1) Proximity switch plate, attached to the sliding rail Easy Move slide sensor Proximity switch plate B-15 Lift arm sensor When successfully installed the ILFP, the Easy Move option has to be activated.
a. Attach your digital voltmeter to the blue (signal) and brown (ground) cables on the J-41 plug b. Voltage should be between 1.4V and 1.6V with gate in stored position i. If necessary rotate B-15 lift arm sensor within oblong hole to achieve voltage range ii. After adjusting B-15 unplug and reattach J-1 plug for reset the signal to board Slide angle sensor B-15 Lift arm Oblong hole in B-15 sensor Voltage difference between store and slide position 0.
6.11 Control box wiring (internal) for turn knob model 10 wire harness ILFP Plus control box setup J11 2 #8 Control Box Backlight bulb J30 (-) 3 14 6 5 4 #6 ON #7 OFF in up out #7 #6 J32 80 81 down #4 #3 #gn/ye SLIDE POS LIFT #4 #3 Hand Control Figure 30 Control box wiring schematic J-2 #2: Main Battery power J-30: Control box PC-board input gate operation functions J-32: Control box PC-board input gate sliding functions (#80 slide in; #81 slide out) 6.
7 Hydraulic schematic Functions: Lift: Lower: Slide Out: Slide In: M+S1+S2 S1+S2+S5+S11 M+S8 M+S7 S1, S2 on lift cylinder and S7, S8 on push pull 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 Figure 31 Hydraulic schematic ILFP Revision 1.
7.1 Lubrication 3 zerks: - 1 cylinder - 1 Lift arm - 1 Parallel arm 3 zerks: - 1 cylinder - 1 Lift arm - 1 Parallel arm 4 zerks: - 1 cylinder - 1 Lift arm - 1 Parallel arm - 1 Swing fixture 4 zerks: - 1 cylinder - 1 Lift arm - 1 Parallel arm - 1 Swing fixture Oil reservoir inside main tube. Pull out tray to check and refill oil.
Decal Placement and Inspection 7.2 For operator’s safety, all decals appearing in “Decal Kit” must be in a conspicuous place on control side of liftgate to be read by operator. This is typically a combination of decals on the liftgate and truck body. Please make sure to place the maximum capacity decal (C) on driver and curb side. (A) 1 ATG-URGWA - Urgent warning: Elevating gate instructions (B) 1 ATG- SWILFP - Main Operation (Control Box) (C) 2 ATG-XXXX - Max.
The picture below will help you to place all decals visible in order to get maximum operational safety. Decal - A Decal - L Decal - C Decal - B Decal - F Decal - H Decal - G Revision 1.
8 Check Off Sheet JOB NO. GATE NO. OWNER'S MANUAL IN CAB ON-OFF SWITCH WORKING & DECAL IN PLACE WIRING 1. Power Cord Secured 2. Cables Not Rubbing Steel 3. 12V Control Wire Secured 4. Loomed & Stapled 5. Circuit Breaker & Fuse VIN NO. OPERATION 1. All Functions Operate On outside Control & Hand Control 2. Up Stops In Place 3. Platform Meets Body 4. Sensor Set For Proper Installed & Decal In Place 6. Loop in platform sensor wire Function 5. Warning lights stop flashing HYD. LINES SECURED 1.
