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