Palfinger Minifix K1Plus Series User manual

1
Minifix-K1Plus –Series (July 2008-today)
Troubleshooting: K1Plus with square circuit board
Table of content: Page
1) Gate overview and connector setup………………....2
2) Gate does not tilt open up…………………………….3
3) Gate is not lowering down…………………………….4
4) Gate is not auto tilting down at ground level…....…..5
5) Gate is not tilting up at ground level..………………..6
6) Gate is not lifting up.…………………………………..7
7) Gate is not closing……………………………………..8
8) Electrical schematic……………………………………9
9) Hydraulic schematic………………………………….10
*****MAKE SURE YOUR BATTERIESARE FULLY CHARGED
AND IN GOOD CONDITION*****
Tools needed:
1.) Voltmeter
2.) Test light
3.) 8” jumper cable (16ga. or smaller)
4.) Screw driver flat head or 13mm (1/2”) wrench

2
Overview of liftgate and schematic of circuit board
CIRCUIT BOARD
POWERPACK
B-13 LIFTARM B-16 PLATFORM GROUND
CONTROLPANEL
CAB CUT OFF SWITCH
FOOT
CONTROL
WARNING
LIGHTS
HANDREMOTE
CYLINDERS
LIFT15 (1 ea)
TILT14 (1 ea)
Release valve S2
Tilt cylinder
B-16 Platform sensor
B-13 Lift arm sensor
Pump & motor
Lift cylinder
Release valve S1
Pump & motor box
Oil tank Shift valve S5 Motor
Motor solenoid
Circuit board

3
1) GATE DOES NOT TILT OPEN UP
a) Check resettable Circuit Breaker on top of battery Push Reset Tab back in, if popped out
b) Check fuse on top of battery (qty 1) and
at circuit board (qty 2) inside pump and motor box at mount frame
c) Start van and run engine in fast idle for charging the battery
if liftgate starts working, recharge batterytest battery and replace if necessary
d) Check power on board between J-11 #4 and J-2 (-) with voltmeter by pushing the
up-function knob and hold for 10 sec with gate in stored position (DEADHEAD GATE)
(above 10 Volt is necessary for proper use of liftgate) less than 10 V; Jump #2 to #4
on J-11voltage jumps more than 1volt, call Palfinger for assistance
****DO NOT LEAVE JUMPER ON J-11 –GATE MUST BE SHUT OFF WHEN NOT IN USE****
1.1) Check Battery Power
a) Unplug J-3(foot control), J-41(B-13, B16, jump J-11 #4 to J-41 #GN) and J-31(Hand control)
Keep the 3 connectors unplugged (gate will operate without plugs connected, loose auto tilt)
b) Unplug J-1 (Main power), wait 10 seconds and plug J-1 back to the board (Reset the board)
c) Plug each connector back, one at a time and check functions of gate after plugging in each
1.2) Check for short in optional equipment
a) Check voltage at J4 #14 and Ground J-2 #(-) while pushing the open knob for opening up the release
valve S2 at the tilt cylinder. No Voltage check for bad knob or loose wire to control panel.
b) Listen for clicking of the release valve at the tilt cylinder (connected to platform)
- If valve is not clicking check wire for damaged spots, loose connections or a bad valve
1.3) Check voltage supply to release valve on tilt cylinder
a) Check voltage at J-1 #3 and Ground J-2 #(-) while pushing knob to engage motor solenoid
No voltage board might be damaged
b) Check voltage at small motor solenoid terminals and Ground J-2 #(-) while pushing knob and
listen for clicking of the motor solenoid –no voltage or clicking check wire to motor solenoid
c) Check for voltage across the small motor solenoid terminals with test light while pushing knob
See a light power is reaching solenoid.
d) Check for main power at the big solenoid studs, one has voltage; if not check connections to battery
e) Check both big solenoid studs for voltage while pushing the opening knob if not solenoid is bad
f) Jump large terminals at motor solenoid
- If motor runs motor solenoid is bad
- If motor does not run Bad motor or bad ground
- Tap on motor motor starts running –bad brushes
1.4) Check motor solenoid power
Minifix +
series

4
2) GATE IS NOT LOWERING DOWN
2.1) Check Battery Power
2.2) Check for short in optional equipment
a) Check voltage between Ground J-2 #(-) to J4 #15 while pushing the lowering knob for opening
the release valve at the lift cylinder. No voltage check for bad knob or loose wire to control knobs
b) Listen for clicking of the release valve at the lift cylinder (connected to lift arm)
If valve is not clicking check wire for damaged spots or loose connections
2.3) Check voltage supply to release valve on lift cylinder
a) Check Voltage at J1 #12 and Ground J-2 #(-) while pushing knob to engage the shift valve S5 at
the pump and motor inside box at main frame underneath van.
b) Override the shift valve by pushing in at the cab of the shift valve while pushing the down knob
Gate will lower down check the valve and look for damaged wire or loose connections
2.4) Gate is lowering down very slowly S5 at motor not engaged
Minifix +
Series
a) Check resettable Circuit Breaker on top of battery Push Reset Tab back in, if popped out
b) Check fuse on top of battery (qty 1) and
at circuit board (qty 2) inside pump and motor box at mount frame
c) Start van and run engine in fast idle for charging the battery
if liftgate starts working, recharge batterytest battery and replace if necessary
d) Check power on board between J-11 #4 and J-2 (-) with voltmeter by pushing the
up-function knob and hold for 10 sec with gate in stored position (DEADHEAD GATE)
(above 10 Volt is necessary for proper use of liftgate) less than 10 V; Jump #2 to #4
on J-11voltage jumps more than 1volt, call Palfinger for assistance
****DO NOT LEAVE JUMPER ON J-11 –GATE MUST BE SHUT OFF WHEN NOT IN USE****
a) Unplug J-3(foot control), J-41(B-13, B16, jump J-11 #4 to J-41 #GN) and J-31(Hand control)
Keep the 3 connectors unplugged (gate will operate without plugs connected, loose auto tilt)
b) Unplug J-1 (Main power), wait 10 seconds and plug J-1 back to the board (Reset the board)
c) Plug each connector back, one at a time and check functions of gate after plugging in each

5
3) GATE IS NOT AUTO TILTING
AT GROUND LEVEL
3.1) Check Battery Power
a) Check the position of the B-13 Sensor on the inside of the passenger side lift arm
Sensor has to be in a horizontal position when gate is 8”-10” above ground
b) Check if the outer J-41 Plug is loose (color sequence = blue, black, brown)
3.2) Check adjustment of auto-tilt sensor B-13
a) Check voltage at J41 #(BLACK)(B-13) to Ground J-2 #(-) while platform is on ground 12V
b) Check voltage at J41 #(BLUE)(B-13) to Ground J-2 #(-) while platform is on ground 12V
No voltage on BLUE Look for damaged spots or loose connection or B-13 is bad
c) Check voltage at J4 #14 to Ground J-2 #(-) while pushing the lowering button when gate is on
ground for opening up the release valve S2 at the tilt cylinder
d) Listen for clicking of the release valve at the tilt cylinder (connected to platform)
If valve is not clicking check wire for damaged spots or loose connections
3.4) Check voltage supply to release valve on tilt cylinder
a.) Check voltage at J30 #4 to Ground J-2 #(-) for power supply of the control buttons
b) Check voltage at J30 #6(lower) to Ground J-2 #(-) for lowering signal by pushing down knob
Signal on J30 #6 control buttons are ok; if no signal check for damaged wire or loose cables
to control buttons or damaged buttons
3.3) Check function of control buttons(J30) and hand control(J31)
Minifix +
Series
a) Check resettable Circuit Breaker on top of battery Push Reset Tab back in, if popped out
b) Check fuse on top of battery (qty 1) and
at circuit board (qty 2) inside pump and motor box at mount frame
c) Start van and run engine in fast idle for charging the battery
if liftgate starts working, recharge batterytest battery and replace if necessary
d) Check power on board between J-11 #4 and J-2 (-) with voltmeter by pushing the
up-function knob and hold for 10 sec with gate in upper position(DEADHEAD GATE)
(above 10 Volt is necessary for proper use of liftgate) less than 10 V; Jump #2 to #4
on J-11voltage jumps more than 1volt, call Palfinger for assistance
****DO NOT LEAVE JUMPER ON J-11 –GATE MUST BE SHUT OFF WHEN NOT IN USE****

6
4) GATE IS NOT TILTING UP AT GROUND
4.1) Check Battery Power
a) Check voltage at J-1 #3 to Ground J-2 #(-) while pushing lift knobs to engage motor solenoid
b) Check for voltage at small motor solenoid terminals and Ground J-2 #(-) while pushing knobs and
listen for clicking of the motor solenoid –no voltage or clicking check wire to motor solenoid
c) Check for voltage across the small motor solenoid terminals with test light while pushing knobs
See a light power is reaching solenoid.
d) Check for main power at the big solenoid studs, one has voltage; if not check connections to battery
e) Check both big solenoid studs for voltage while pushing the lifting buttons if not solenoid is bad
f) Jump large terminals at motor solenoid
- If motor runs motor solenoid is bad
- If motor does not run Bad motor or bad ground
- Tap on motor motor starts running –bad brushes
4.3) Check motor solenoid power to run the motor
a) Check voltage at J1 #12 and Ground J-2 #(-) while pushing buttons to engage the shift valve at
the pump and motor inside the main tube
b) While pushing the knobs to make the motor run, override shift valve S5 by pushing in at the cab of the
valve Gate will tilt up, if not check the valve and look for damaged wire or loose connections
4.4) Check function of shift valve S5 at pump & motor
a) Check voltage at J30 #4 to Ground J-2 #(-) for power supply of the control buttons
b) Check voltage at J30 #5(lift) to Ground J-2 #(-) for lifting signal by pushing up buttons
Signal on J30 #5 control buttons are ok; if no signal check for damaged wire or loose cables
at control buttons or damaged buttons.
4.2) Check function of control buttons(J-30) and hand control(J31)
Minifix +
Series
a) Check resettable Circuit Breaker on top of battery Push Reset Tab back in, if popped out
b) Check fuse on top of battery (qty 1) and
at circuit board (qty 2) inside pump and motor box at mount frame
c) Start van and run engine in fast idle for charging the battery
if liftgate starts working, recharge batterytest battery and replace if necessary
d) Check power on board between J-11 #4 and J-2 (-) with voltmeter by pushing the
up-function knob and hold for 10 sec with gate in upper position(DEADHEAD GATE)
(above 10 Volt is necessary for proper use of liftgate) less than 10 V; Jump #2 to #4
on J-11voltage jumps more than 1volt, call Palfinger for assistance
****DO NOT LEAVE JUMPER ON J-11 –GATE MUST BE SHUT OFF WHEN NOT IN USE****

7
5) GATE IS NOT LIFTING UP
a) Check resettable Circuit Breaker on top of battery Push Reset Tab back in, if popped out.
b) Check fuse on top of battery (qty 1) and
at circuit board (qty 2) inside pump and motor box at mount frame
c) Start van and run engine in fast idle for charging the battery
if liftgate start working, recharge battery test battery and replace if necessary
d) Check power on board between J-11 #4 and J-2 #(-) with voltmeter while pushing lift up buttons
(above 10 volt is necessary for proper use of liftgate) less than 10V; Jump #2 to #4
on J-11 voltage jumps more than 1 volt, call Palfinger for assistance
****DO NOT LEAVE JUMPER ON J-11 –GATE MUST BE SHUT OFF WHEN NOT IN USE****
5.1) Check Battery Power
a) Unplug J-3(foot control), J-41(B-13, B16, jump J-11 #4 to J-41 #GN) and J-31(Hand control)
Keep the 3 connectors unplugged (gate also operates without plugs connected)
b) Unplug J-1 (Main power), wait 10 seconds and plug J-1 back to the board (Reset the board)
c) Plug each connector back - one at a time - and check functions of gate after plugging in each.
5.3) Check for short in optional equipment
a) Check for voltage at J-1 #3 to Ground J-2 #(-) to engage motor solenoid while pushing lift knobs
b) Check for voltage at small motor solenoid terminals to Ground J-2 #(-) while pushing knobs and
listen for clicking of the motor solenoid –no voltage or clicking check wire to motor solenoid
c) Check voltage across the small motor solenoid terminals with test light while pushing knobs
See a light power is reaching solenoid
d) Check for main power at the large solenoid studs, one has voltage; if not check connections to battery
e) Check both big solenoid studs for voltage while pushing the opening knobs if not solenoid is bad
f) Jump large terminals at motor solenoid
- If motor runs motor solenoid is bad
- If motor does not run Bad motor or bad ground
- Tap on motor motor starts running –bad brushes
5.4) Check motor solenoid power to run the motor
a) Check voltage at J30 #4 to Ground J-2 #(-) for power supply of the control buttons
b) Check voltage at J30 #5(lift) to Ground J-2 #(-) for lifting signal
Signal on J30 #5 control buttons are ok; if no signal - check for damaged wire or loose cables
to control buttons or damaged buttons
5.2) Check function of control buttons(J30) and hand control(J31)
Minifix +
Series

8
6) GATE IS NOT CLOSING
6.1) Check Battery Power
a) Check voltage at J-1 #3 and Ground J-2 #(-) to engage motor solenoid while pushing closing buttons
b) Check voltage at small motor solenoid terminals and Ground J-2 #(-) while pushing knobs and
listen for clicking of the motor solenoid –no voltage or clicking check wire to motor solenoid
c) Check voltage across the small motor solenoid terminals with test light while pushing buttons
See a light power is reaching solenoid
d) Check main power at the large solenoid studs, one has voltage; if not check connections to battery
e) Check both big solenoid studs for voltage while pushing the closing buttons if not solenoid is bad
f) Jump large terminals at motor solenoid
- If motor runs motor solenoid is bad
- If motor does not run Bad motor or bad ground
- Tap on motor motor starts running –bad brushes
6.4) Check motor solenoid power to run the motor
a) Check voltage at J30 #4 to Ground J-2 #(-) for power supply of the control buttons
b) Check voltage at J30 #3(close) to Ground J-2 #(-) for lifting signal while pushing the buttons.
Signal on J30 #3 control buttons are ok; if no signal, check for damaged wire or loose cables
inside control buttons or damaged buttons
6.2) Check function of control buttons(J30) and hand control(J31)
a) Check Voltage at J1 #12 and Ground J-2 #(-) while pushing buttons to engage the shift valve S5 at
the pump and motor inside box at mount frame underneath van
b) Override the shift valve S5 by pushing in at the cab on shift valve S5 while pushing the buttons
Gate will close up check the valve and look for damaged wire or loose connections
6.3) Check for S5 valve on pump & motor not engaged
Minifix +
Series
a) Check resettable Circuit Breaker on top of battery Push Reset Tab back in, if popped out
b) Check fuse on top of battery (qty 1) and
at circuit board (qty 2) inside pump and motor box at mount frame
c) Start van and run engine in fast idle for charging the battery
if liftgate starts working, recharge batterytest battery and replace if necessary
d) Check power on board between J-11 #4 and J-2 (-) with voltmeter by pushing the
up-function knob and hold for 10 sec with gate in upper position(DEADHEAD GATE)
(above 10 Volt is necessary for proper use of liftgate) less than 10 V; Jump #2 to #4
on J-11voltage jumps more than 1volt, call Interlift for assistance
****DO NOT LEAVE JUMPER ON J-11 –GATE MUST BE SHUT OFF WHEN NOT IN USE****

9
150
WIRELESS HANDCONTROL
OPTIONAL
OPTIONAL
WARNINGLIGHTS & FOOTCONTROL
4WIRE CABLE
# 2 BLACK # 4 BLACK # 1 BLACK GREEN / YELLOW
(+)
(-)
LI : Lift Up LO : Lower Down OP : Open Gate CL : Close Gate
CIRCUITBOARD
Legend
:
gn : green bl : blue br : brown wt : white ye : yellow bk : black gy : green-yellow
Electrical schematic

Functions:
Lift:M
Lower:S1+ S5
Tilt Up: M+S5
Tilt Down: S2
Horiz. Open: M+S2
Pressure Relief
2850 PSI
200 bar
Shift Valve S5
Restrictor Valve R5
Flow Divider
Functions:
S1 = Release Valve for lowering function
S2 = Release Valve for tilt down function
R1 = Flow Restrictor located inside hose adaptor on lift cylinder
R2 = Flow Restrictor located inside hose adaptor on tilt cylinder
S5 = Shift Valve is activated on tilt up and lowering function
R5 = Restrictor Valve located in power pack
Flow Divider is activated, when fluid is going back into the power pack
If Flow Divider is loose or hanging up the fluid is circulated back in to tank
2
2
10
Hydraulic schematic
Minifix
K1Plus
Series