Palfinger ILK 22 User manual

ILK
INSTALLATION MANUAL
& CHECK-OFF SHEET
ECN-M1508 Rev. 1.6, Date 09-21-20 Part #90-0413-200
PALFINGER Liftgates, LLC. 15939 Piuma Ave., Cerritos, CA 90703
Tel [phone] Fax [phone]
PALFINGER Liftgates, LLC. 572 Whitehead Road, Trenton, NJ 08619
Tel [phone] Fax [phone]
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

ILK 22/33/44/55/66 INSTALLATION MANUAL
Revision 1.6 - 2 -
Table of Contents
Manual Updates......................................................................................................................................3
Recommended Tools for Installation....................................................................................................3
Important Notes:.......................................................................................................................4
Gate Overview and Components.............................................................................................6
Dimension Sheets ....................................................................................................................8
3.1 Installation Dimensions ILK22 and ILK 33- “Low Mount” 700 mm arm ..........................10
3.2 Installation Dimensions ILK33, ILK44, ILK55 800mm arm............................................11
3.3 Installation Dimensions ILK66 900mm arm..................................................................12
Chassis and Body Preparation for special applications........................................................13
4.1 Flip-Up door & Full-door seal kit installation..................................................................13
4.2 Swing door applications................................................................................................15
Gate and Platform Installation.................................................................................................16
5.1 Sill Preparation .............................................................................................................16
5.2 Installation with mounting fixture...................................................................................16
5.3 Bolt-On Mount Plate Installation –ILK 22/33/44/55.......................................................19
5.3.1 Mount Plate Installation...................................................................................20
5.4 Platform Installation ......................................................................................................23
5.4.1 Attach platform to liftarm..................................................................................23
5.4.2 Installation and Adjusting the tilt cylinders .......................................................23
5.5 Installation without mount fixture...................................................................................25
5.6 Setting and Operation of B-15 Sensor...........................................................................26
5.7 Setting and Operation of B-13 Sensor...........................................................................27
5.8 Installation of left and right Up Stops.............................................................................28
5.9 Fork lift locks installation for re-enforced platforms........................................................29
5.10 Final Welding................................................................................................................29
Electrical Installation................................................................................................................30
6.1 Main Power Connections..............................................................................................30
On-Off Switch Installation Truck Application (In Cab)..................................................................33
6.2 On-off Switch Trailer application ...................................................................................34
6.3 Remote Hand Control Installation .................................................................................35
6.4 Plug and Socket application setups...............................................................................36
6.5 Foot Control installation ................................................................................................39
6.6 Wiring Diagrams ...........................................................................................................40
6.7 Hydraulic Schematic .....................................................................................................42

ILK 22/33/44/55/66 INSTALLATION MANUAL
Revision 1.6 - 3 -
Lubrication and Final Inspection.............................................................................................43
7.1 Decal Placement and Inspection...................................................................................44
Check Off Sheet........................................................................................................................47
Manual Updates
Revision
Description
V1.6
•Updated mount plate installation instructions, Section 5.3
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.

ILK 22/33/44/55/66 INSTALLATION MANUAL
Revision 1.6 - 4 -
Important Notes:
1. Read Manual completely before beginning any work
2. Mount fixture must be ordered separately (for Part number refer to Error! Reference source not f
ound. )
3. Refer to your truck manufacturer’s instructions before adding any auxiliary equipment.
4. Pay Special attention to items marked with this symbol:
5. All welding should be performed by qualified personnel per AWS standards
6. For flip up door or full seal kit applications, please read 4.1 first
7. For swing door applications, please read 4.2 first
8. Always Ground closest to your welding point to prevent arcing through moving parts
9. Contact PALFINGER Liftgates, LLC for Special Installations not covered in this Installation Manual
10. Do not paint cylinder shafts or nylon rollers (Use non-chlorinated brake cleaner to remove
over spray)
11. Verify that pin lock bolts are tight
12. Grease all pivot points
13. Verify that ALL decals are placed properly (Contact PALFINGER Liftgates replace any missing de-
cals)
14. Final Check-Off-Sheet at rear of this manual MUST be filled out and kept in your records for
future reference.
15. Refer to owner’s manual for troubleshooting & repairs.
Important Dimensions:
(Refer to line drawing on following pages)
1) BED HEIGHT [H] Bed Height Ranges: Max=Unloaded / Min=Loaded Truck
•Measure from top of body floor to ground. Vehicle must be on flat level ground when
measured.
2) MOUNT TUBE HEIGHT [F]
•Measure from TOP of Mount Tube to TOP of body floor
3) MOUNT TUBE [K]
•Measure from rear of body to forward edge of Mount Plate.
4) REAR SILL CUT OUT [S]
•Refer to H, K &S Charts and Cut Out diagrams on following pages
5) GROUND CLEARANCE
•Measure from BOTTOM of Mount Tube to ground

ILK 22/33/44/55/66 INSTALLATION MANUAL
Revision 1.6 - 5 -
Mounting Notes:
Read and clearly understand manual BEFORE beginning ANY work
Important!!!
The basic rule of PALFINGER Liftgates ILK 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

ILK 22/33/44/55/66 INSTALLATION MANUAL
Revision 1.6 - 6 -
3 Button Hand control
Mount frame
Tilt Cylinder
(outside of the Frame)
Lift Arm
Lift Cylinder
Platform
Warning Lights
Center of Gravity of
maximum load
Cart Stops
(optional)
Foot control
(optional)
Platform
sensor B15
(under the
platform)
Rear bumper
Hydraulic Power Unit on
slide tray
(inside the mount frame)
Lift arm sensor
B13
Serial Tag
Control box
Circuit Board
(behind cover)
Gate Overview and Components

ILK 22/33/44/55/66 INSTALLATION MANUAL
Revision 1.6 - 7 -
NOTES

ILK 22/33/44/55/66 INSTALLATION MANUAL
Revision 1.6 - 8 -
Dimension Sheets
A= Bedheight:.....................................________ Loaded Bedheight:.....................................________
B = Top of floor to bottom of frame:.............................................................................................________
C = Rear sill height:.......................................................................................................................________
D = Spring hanger to end of body (if applicable):......................................................................________
E =Air bag suspension to end of body (if applicable):..............................................................________
F = Tire to end of vehicle body:....................................................................................................________
G = Gas tank to end of body (if applicable):................................................................................________
H = Fuel filler hole to end of body (if applicable):......................................................................________
I = Bottom of frame to bottom of gas tank (if applicable):........................................................________
J = Top of floor to bottom of sliding walk ramp (if applicable):.................................................________
K = Frame Width: Width of chassis frame:..................................................................................________
L= Frame Height: Height of chassis frame:................................................................................________
Truck Information
Truck Dimensions
Type of Body (check applicable)
Van
Flatbed
Reefer
Other (specify)____________
Type of Rear Door (check applicable)
Flip-Up
Roll-Up
Swing
Other (specify)________________
Truck Specifications:
Manufacturer: (ex. Hino)
GVWR: (ex. 68,000 lbs)
Length: (ex. 53ft)
Width: (96", 102")
Truck Chassis Dimension Sheet
Liftgates Information:
Model
Capacity
PlatformSize
PlatformMaterial
90-9813-003_b
Notes:
Side View of Truck Rear View of Truck
Walk Ramp (if applicable)
A
B
C
D
E
F
G
J
H
IK
L
Customer Information
Quote#/SO#:____________________________________________________
Company:______________________________________________________
Phone:_________________________________________________________
Email: _________________________@______________________________

ILK 22/33/44/55/66 INSTALLATION MANUAL
Revision 1.6 - 9 -
A= Bedheight: Top of trailer floor to level ground (with airbags up):........................................................................________
B = Top of floor to bottom of trailer cross member:.....................................................................................................________
C = Rear sill height (Top of floor tobottomof buckplate): If Stepped sill complete M,N; If Tapered sill completeO, P.
D = Crossmember height:...............................................................................................................................................________
.
E = Tire to end of vehicle body:......................................................................................................................................________
F = Bogie to end of vehicle body................................................________ Sliding Suspension?Yes________ No________
IfYes complete G, H, I, K, and Ldimensions
G = Inside horizontal width of sliding suspension angles:.........................................................................................________
H = Diameter of sliding suspension holes:...................................................................................................................________
.
I = Hole spacing:..............................................................................................................................................................________
J =Bottomof crossmembers to bottomof sliding ramp box, if applicable:.............................................................________
K = Rear sill face to first sliderhole:.............................................................................................................................________
L = Top of floor, where liftgate platform will meet floor, to the center of the trailer slider holes:............................________
X = Eyebrow depth:.........................................................................................................................................................________
Z = Top of floor, where the liftgate platform will meet the top of the eyebrow:.........................................................________
Customer Information
Quote#/SO#:____________________________________________________
Company:______________________________________________________
Phone:_________________________________________________________
Email: _________________________@______________________________
Trailer Information
Trailer Dimensions
Type of Body (check applicable)
Van
Flatbed
Reefer
Other (specify)____________
Type of Rear Door (check applicable)
Flip-Up
Roll-Up
Swing
Other (specify)________________
Trailer Specifications:
Manufacturer: (ex. Utility)
GVWR: (ex. 68,000 lbs)
Length: (ex. 53ft)
Width: (96", 102")
Trailer Chassis Dimension Sheet
Liftgates Information:
Model:
Capacity:
PlatformSize:
PlatformMaterial:
90-9813-002_b
Flush Stepped Tapered
M = ________
N = ________
O = ________
P = ________
A
BC
D
EF
G
Side View of Trailer Rear View of Trailer
X
Z
LK
ø
HI
Walk Ramp (if applicable)
J
M
N
O
P
Notes:
C
C = ________

ILK 22/33/44/55/66 INSTALLATION MANUAL
Revision 1.6 - 10 -
3.1 Installation Dimensions ILK22 and ILK 33- “Low Mount” 700 mm arm
IMPORTANT:
Always use the smallest F-dim possible for best ground clearance (do not exceed max. ground clearance!)
Max ground clearance18.5" (never exceed max)
Mingroundclearance9.5"
Groundclearance= bedheight- F-dim- 7"
Maxbedheight 49.5" Minbed height 30"
F-dim. - Min13" Max 24"
Fdim.
Kdim.
700 mm27.5"
24
23
22
21
20
19
18
17
16
15
14
13
25262728293031 32 333435
K-dim. - Min 25"
Max35"
4.50
4.50
4.25
4.25
4.00
4.00
3.75
3.75
3.50
3.50
3.25
Sdim.
11"
Sdim. 38"
7"
WhentheK-Dim. isMAX, theF-Dim. isMIN
Figure 3.1: ILK22 and ILK33 Installation table
Part number for ILK 22 Mounting Fixture: 1-00015, Part number for ILK 33 Mounting Fixture: 1-00016
ILK22 comes with 2 different mount plates (bolted or welded)
MINIMUM bed height is defined as truck/trailer loaded to MAX GVW

ILK 22/33/44/55/66 INSTALLATION MANUAL
Revision 1.6 - 11 -
3.2 Installation Dimensions ILK33, ILK44, ILK55 800mm arm
IMPORTANT:
Always use the smallest F-dim possible for best ground clearance (don’t exceed max. ground clearance!)
Maxgroundclearance21"(neverexceedmax)
Mingroundclearance10"
Groundclearance=bedheight-F-dim- 7"
Maxbedheight56" Minbedheight 36"
F-dim. - Min 18" Max28"
Fdim.
Kdim.
28
26
24
23
22
21
20
19
18
29 30 31 32 33 34 35 36 37
K-dim. - Min 25"
Max35"
800mm31.5"arm
WhentheK-dimismaxtheF-dimisthemin.
5.25
5.00
4.75
4.50
4.25
4.25
4.00
4.00
Sdim.
7"
10"
Sdim. 49"
Figure 3.2: ILK33, ILK44, ILK55 installation table
Part number for ILK 33 Mounting Fixture: 1-00016, for ILK 44 and ILK 55 Mounting Fixture: 1-00017
MINIMUM bed height is defined as truck/trailer loaded to MAX GVW
Note: Special arm sizes available for different installation circumstances
11“

ILK 22/33/44/55/66 INSTALLATION MANUAL
Revision 1.6 - 12 -
3.3 Installation Dimensions ILK66 900mm arm
IMPORTANT:
Always use the smallest F-dim possible for best ground clearance (do not exceed max. ground clearance!)
Maxgroundclearance22.5"(neverexceedmax)
Mingroundclearance11.5"
Groundclearance=bedheight- Fdim- 7.5"
Maxbedheight60" Minbedheight40"
F-dim. - Min 21" Max31"
Fdim.
Kdim.
31
29
27
26
25
24
23
22
21
32 33 34353637 38 3940 41 42
K-dim. - Min 32"
Max 42"
900mm35.5"arm
WhentheK-dimismaxtheF-dimisthemin.
5.25
5.00
4.75
4.50
4.25
4.25
4.00
4.00
Sdim.
7.5"
10"
Sdim. 49"
Figure 3.3: ILK66 installation table
Part number for ILK 66 Mounting Fixture: 1-00018
MINIMUM bed height is defined as truck/trailer loaded to MAX GVW

ILK 22/33/44/55/66 INSTALLATION MANUAL
Revision 1.6 - 13 -
Chassis and Body Preparation for special applications
4.1 Flip-Up door & Full-door seal kit installation
1.Install ½” x 1-1/2” HR flat bar to the lower rear body seal
Figure 4.1: Full door seal kit
2.Install gate per instructions per 5.1
Rear Lower Body Sill
1/2" x1-1/2" HR Flat
T I R E T I R E
Gasket Channel
Gasket Channel (Full Door Kit Only)

ILK 22/33/44/55/66 INSTALLATION MANUAL
Revision 1.6 - 14 -
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 in
down position
3.Install gasket channels on rear vertical body posts to make contact with the platform surface.
Gasket must NOT make contact with platform edge caps. Doing so will cause leaks.
4.For full door seal kits install gasket channel along header at edge of platform
Figure 4.2: 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 approx. 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

ILK 22/33/44/55/66 INSTALLATION MANUAL
Revision 1.6 - 15 -
4.2 Swing door applications
A bridge kit is recommended for the usage of an ILK liftgate behind swing doors. Due
to the shifted pivot points all welding and cut out points have to be shifted according-
ly.
3" Channel (Bridge Kit)
Notch Channel To Clear
Door Latch Hardware
Top View
Side View
Full Weld
(Weld toArm
ONLY
)
Bridge Kit Detail
1/2"x2" HRFlat
3"x4.1 Channel
When using 3" channel bridge
install liftgate so platform is
3-1/2" to 3-3/4" fromdoor gasket
when door is closed
CL
Figure 4.3: Bridge kit for swing doors
Please consider your particular door frame. Set up for best solution for your application.

ILK 22/33/44/55/66 INSTALLATION MANUAL
Revision 1.6 - 16 -
Gate and Platform Installation
Refer to 4.1 for flip-up door/full seal kit and swing door applications BEFORE INSTALLATION
Refer to 5.2 for installs with Mounting Fixture BEFORE INSTALLATION
5.1 Sill Preparation
1. Reinforce back sill by welding a ½” flat bar to the rear, 8 welds each on top and bottom.
2. Notch rear sill, if necessary, per installation table (Section 3.1) for your particular model.
3. Box in notch with flat bar to maintain sill strength.
5.2 Installation with mounting fixture
1. Locate and mark out the center of the rear body or bed sill.
2. Attach the PALFINGER Liftgates mounting fixture centered to the sill by tack welding it in place.
(The mounting fixture must be ordered separately from PALFINGER Liftgates. Once purchased it
can be used over and over)
3. Tie tilt cylinders with rope or wire to lift arm to avoid dragging on the ground
Figure 5.1: Mount fixture welded to rear sill
4. Prepare the body for the mount plates. The mount plates lie flat against body rail/ truck frame/ sub
frame.
5. Slide mount tube under the truck frame/ sub frame and attach the lift arm to the mounting fixture. At
this point you should place the mount tube in the pre-determined position, keeping the given maxi-
mums and minimums in mind (K- and F- dimensions). Use a forklift, a floor jack or a similar device
to position the mount tube. Make sure the mount tube is placed at a 90-degree angle to the
truck bed.
Attach lift arm here
Always make sure to
pursuit the policy of
MAXIMUM GROUND
CLEARANCE
BACKVIEW
Mounting Fixture
SIDEVIEW

ILK 22/33/44/55/66 INSTALLATION MANUAL
Revision 1.6 - 17 -
Mount Fixture
Maintain Parallel with
Truck Body floor
LiftArm
Mount Fixture as shown
90.00°
Figure 5.2: Mount frame alignment with fixture
6. With the mount tube held in place, position the mount plates over tube and against truck frame. Po-
sition them with angle facing to back of truck and clamp them to truck frame.
7. Refer to 5.3 for Bolt-On Mount Plates for model ILK22 only
Before any welding is started, 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.
Be certain to pull out power tray before welding. IMPORTANT!!!!!!
8. The reservoir is made of plastic and you will burn it while welding. To pull out tray, open curb side
mount tube rubber cover, simply remove the clamp and the tray holding bolt and detach the ground
strap and control power connector for the tray. Pull on tray until the hoses are stretched and the tank
is further out than the point of welding, open driver side to verify that hoses or cables are not touch-
ing inside of tube wall. Insulate the inside of the mount tube to protect the hoses from the heat dur-
ing welding
Reservoir
Mount Frame Door &
Control PCB
Pump
Bolt Tab
Mount Frame
Pull Out
Mount Plate

ILK 22/33/44/55/66 INSTALLATION MANUAL
Revision 1.6 - 18 -
9. Tack weld mount plates to mount tube with a minimum of three 2” and three 2” welds to the truck
frame.
Before finishing up all welding we recommend doing the electrical installation (see 6, Page 30)
and platform installation (see 5.4, Page 23) to make sure that everything aligns like it should.
Use a min of 8" overlap between mount plates and truck frame.
Weld 100%with 1/4" weldagainst the frame, also weld
inside and ouside of the plates against the mount frame.
Install Lower Gusset Supplied
ON 5500 and 6600LB Units
ONLY
8" overlap
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 free of obstruction while cycling gate. Verify curb side and driver side.
Lift
Cylinder Solenoid
Lift
Arm

ILK 22/33/44/55/66 INSTALLATION MANUAL
Revision 1.6 - 19 -
5.3 Bolt-On Mount Plate Installation –ILK 22/33/44/55
IMPORTANT: When drilling into the vehicles C-Channels, make sure to observe the vehicle
manufacture’s guidelines and recommendations before drilling.
When installing the mount plates on a C-Chassis use the following amount of bolts listed below
along with their torque specificaitons:
Model
No. of Bolts
Bolt Type
Torque Specification
ILK 18
4
14 x 1.5
St. 10.9
140 ft./lbs. [140 Nm]
ILK 22
4
ILQ 22
4
ILK 33
6
ILK 44-55
10
ILK 66
14
Before If it is necessary to perform any welding make sure to slide out the power pack out of
the mount tube to prevent any damage to the oil tank.
Bolt Spacing
1. Space bolts approximately 2” from the edge of the plates.
2.00" 2.00"

ILK 22/33/44/55/66 INSTALLATION MANUAL
Revision 1.6 - 20 -
5.3.1 Mount Plate Installation
ILK 22 Bolted Mount Plates
1) Set up mount plates (2) on top of mount frame (1)
2) Connect mount plate (2) to mount frame (1) with Hex head bolts (3), lock washer (4) and (5) square
washer.
3) Slide mount plates in position to frame width and slide gate under truck frame.
4) Tack weld mount plates (2) to frame when gate is in position and aligned.
5) Double-check position of gate (centered underneath the truck)
6) Tighten up hex head screws (3) to secure mount frame (1) and mount plates (2).
Torque on screws (5) = 295 ft./lbs. [400 Nm].
2
5
1
2
3
4
5
4
3