Palfinger ILP 25 User manual

INSTALLATION MANUAL
& CHECK OFF SHEET
ILP 25, 2500 lbs. Capacity
ILP 33, 3300 lbs. Capacity
02/19

ILP 25/33 Installation Manual
Rev. 1.4 - 2 -
ILP 25/33 Installation Manual
Document Part Number: 90-0116-000 / 16-684_90-00_00-00
ECN-M1301, Rev. 1.4, 02-01-19
Copyright © 2019 Palfinger Liftgates LLC.
All rights reserved.
Information in this document is subject to change without notice.
Visit www.palfinger.com for up to date information and notifications.
If you received this product with damaged or missing parts,
contact Palfinger Liftgates at (888)-774-5844
15939 Piuma Ave.
Cerritos, CA 90703
Tel [phone]
Fax [phone]
572 Whitehead Road.
Trenton, NJ 08619
Tel [phone]
Fax [phone]

ILP 25/33 Installation Manual
Rev. 1.4 - 3 -
Table of Contents
1Manual Updates........................................................................................................................5
2Safety Information....................................................................................................................6
3Important Information ..............................................................................................................7
4Tools For Installation ...............................................................................................................9
4.1 Boxed Items..................................................................................................................9
5General View of Liftgate(s).......................................................................................................10
5.1 ILP General Overview...................................................................................................10
5.2 Important Dimensions...................................................................................................11
6Installation Dimensions ...........................................................................................................12
7Platform Compatibility .............................................................................................................14
8Chassis and Body Preparation - 800mm [31.50“] Liftarm......................................................15
9Chassis and Body Preparation - 900mm [35.40“] Liftarm......................................................16
10 Gate Installation........................................................................................................................17
10.1 Sill Cutouts....................................................................................................................17
11 Bed Extension Installation.......................................................................................................18
11.1 Bed Extension (Weld-On) .............................................................................................18
11.2 Bed Extension (Bolt-On) ...............................................................................................22
12 Liftgate Installation (Truck)......................................................................................................24
12.1 Liftgate Installation........................................................................................................24
12.2 Adjusting the Platform...................................................................................................32
12.3 Final Steps of Installation..............................................................................................36
12.4 Sub-frame Installation (Optional)...................................................................................37
12.5 Dock Bumper Installation - Weld-On (Optional).............................................................38
12.6 Dock Bumper Installation - Bolt On (Optional)...............................................................39
12.7Walkramp Cradle Installation (Optional)........................................................................41
13 Electrical Installation................................................................................................................46
13.1 Electrical Wiring –Batteries –Truck/Trailer...................................................................47
13.2 Cable Routing...............................................................................................................48
13.3 Connecting Power to Liftgate........................................................................................48
13.4 Wire Crimping...............................................................................................................49
13.5 Circuit Breaker Installation ............................................................................................49
13.6 Toggle Switch Installation .............................................................................................50
13.7 Liftgate Shut-Off Switch ................................................................................................52
13.8 2-Button Hand Held Remote Control (Optional)............................................................54
13.9 Electrical Schematic (Gravity Down).............................................................................56

ILP 25/33 Installation Manual
Rev. 1.4 - 4 -
13.10 Electrical Schematic (Power Down ) .............................................................................57
14 Hydraulic Schematic (Gravity Down) ......................................................................................58
14.1 Hydraulic Schematic (Power Down)..............................................................................59
14.2 Hydraulic Fluid..............................................................................................................60
15 Decal Placement and Inspection.............................................................................................61
16 Lubrication................................................................................................................................63
17 Final Inspection Check List .....................................................................................................64
Company Information:
Company Name:
Advisor Name:
Vehicle Year Make & Model:
Liftgate Information:
Liftgate Serial Number:
Liftgate Model Number:
Date of Purchase:
Date of Installation:

ILP 25/33 Installation Manual
Rev. 1.4 - 5 -
1 Manual Updates
Revision
Description
v1.1
Changed product name from PLP to ILP.
Updated F-Dimensions on Section 8.
v1.2
Added walkramp Section 12.7.
Revised Sections 13.9, 13-10: Toggle switch wire colors updated.
v1.3
Section 6: Dimension Sheets
Updated Section 11.2: Updated bolt-on hole pattern.
Section 12 (all): Updated steps and detailed instructions.
Section 12.3: Bolt removal from swing fixture
Section 13.9-13.10: Power and Gravity Down wiring schematics
v1.4
Updated pictorials throughout manual to match actual product.

ILP 25/33 Installation Manual
Rev. 1.4 - 6 -
2 Safety Information
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.
! CAUTION indicates a potentially hazardous situation which, if not avoided, may result in minor or
moderate injury.
CAUTION without the safety alert symbol is used to address practices not related to personal injury.
(In this manual it is used to alert the user to potentially hazardous situation which, if not avoided, may result
in property damage.)
NOTICE without the safety alert symbol is used to address practices not related to personal injury. (In this
manual it is to alert you to special instructions, steps, or procedures.)
Always be aware of your surroundings.
Wear eye protection at all times during installation.
Ear protection and gloves should be used when necessary.
Improper operation of this liftgate may result in severe personal injury or death. DO NOT operate
unless you have been properly instructed, have read and are familiar with the procedures in this
manual. This manual has been designed to illustrate the steps needed for the basic installation of
the ILP liftgate. It also provides safety information and simple preventive maintenance tips.

ILP 25/33 Installation Manual
Rev. 1.4 - 7 -
3 Important Information
Before Getting Started
“READ FIRST”
The ILP liftgate is a heavy duty industrial hydraulic lifting device. Performance and reliability are
closely related to proper installation, battery cable connections, and grounding. All grounding
surfaces MUST be cleaned, prepped, and sealed per this manual. “Cut to size” cables MUST be
properly crimped and sealed as factory supplied. All connections MUST be dressed with dielectric
grease or equivalent sealer.
Review liftgate invoice, packing slip, and installation drawing to assure delivery of correct gate and
complete delivery of accessories and optional equipment.
Refer to Section 8 and verify that the truck/trailer has sufficient bed height and mount clearance for the
selected gate. Keep in mind that the truck/trailer can settle several inches depending on suspension,
over hang, addition of equipment and loading.
1. If the minimum bed height is not maintained the gate will not fold or unfold
2. If the maximum bed height is exceeded the gate may not reach the ground
Read and understand the “Installation Manual” and “Owner’s Manual” in their entirety before starting
the installation.
Refer to your truck manufacturer’s instructions before adding any auxiliary equipment. Installer is
responsible for compliance with this manual, OEM and FMVSS requirements.
All welding should be performed by qualified personnel per AWS standards.
Always Ground closest to your welding point to prevent arcing through moving parts or electrical parts.
Contact Palfinger Liftgates for Special Installations not covered in this Installation Manual.
Do not paint cylinder shafts or nylon bearings (Use non-chlorinated brake cleaner to remove over
spray)
Final Check-Off-Sheet at rear of this manual MUST be filled out and sent to Palfinger Liftgates for
warranty activation.
Refer to Owner’s Manual for Operation and maintenance information.
Check the battery voltage before installation. Flooded lead acid batteries should measure 12.6V and
AGM batteries should measure 12.8V. If batteries are not at these voltages, fully charge before
installation.

ILP 25/33 Installation Manual
Rev. 1.4 - 8 -
This manual is not intended for use as a repair or troubleshooting guide. Repairs should be
performed by a Palfinger Liftgates Authorized Service Center.
This Manual has been designed for use in conjunction with the ILP series liftgate only which is designed for
different capacities and features.
1) Refer to the serial number tag on the liftgate, it can be found on the driver side liftaftm, as shown in
Fig.1.
Serial
Number
Tag
Liftarm
(Driver Side)
2) Ask your employer or lessor;
3) Call your Palfinger Liftgates Authorized Service Center for assistance.
4) Call Palfinger Liftgates for assistance in the USA at 888-774-5844. You can also contact Palfinger
Liftgates by fax [phone] or on the internet at www.palfinger.com
For technical support, contact Palfinger Liftgates or an authorized Palfinger service center.
www.palfinger.com
Fig.1

ILP 25/33 Installation Manual
Rev. 1.4 - 9 -
4 Tools For Installation
Metric Wrench Set
Basic Screwdrivers
Assorted Pliers
Wire Crimp Pliers
Digital Multi-Meter
Snap Ring Pliers
Hammer
SAE & Metric Allen key Set
½” Impact & Sockets
SAE & Metric Socket
Set
Assorted Drill
Bits
Floor Jack or Equiv.
Small to medium bottle
Jack
Forklift or Over Head
Crane
Hand Held
Grinder
Paint Gun & Accessories
Pry Bar
3/8 Drill Motor
Grease Gun
Heat Gun or Equiv.
Min. 250 Amp Welder
Cutting Torch or Equiv.
Safety Goggles
Framing Square
4.1 Boxed Items
Installation for each boxed item can be found throughout this installation manual.
Heat Shrink,
ø1/2" x 3"L
1 pc Copper
Bus Bar
1 pc
Circuit Breaker
1 pc
Owner's Manual
1 pc Installation Manual
1 pc
Battery Lug, 5/16"
1 pc
Decal Kit
13 pcs
8" Nylon Cable Tie
15 pcs
Power Cable
1 pc Shut Off Switch
1 pc
Toggle Switch
1 pc
For Trailers
For Trucks

ILP 25/33 Installation Manual
Rev. 1.4 - 10 -
5 General View of Liftgate(s)
5.1 ILP General Overview
Available Options:
Lift Capacities: 2500 lbs. or 3300 lbs.
Power Down (Electrical) –Power (motor) assisted operation for lowering platform.
Power Down (Mechanical) –Spring assisted operation for lowering platform.
Standard Configuration - No bumper Fig.2.
Center Bumper- Three piece bumper assembly positioned in the center of the mount frame. Fig.3.
DOT Bumper- Three section bumper that meets Department of Transportation requirements. Fig.4.
Hitch Bumper –Three piece assembly with hitch receiver and “D” rings Fig.5.
*No spring installed on left side for 42“ and 48“ aluminum platforms only
Load Center
of Gravity
DOT Bumper Hitch Bumper
Center Bumper
Hydraulic
Power Unit
Liftarm
ParallelArm
Platform
Cart Stops
(Optional)
SingleAction or
DoubleAction
Lift Cylinders
Springs*
Hydraulic
Power
Unit Platform
Roll Off
Wheels
Bolt-On
Mount Plates
Mount
Frame
Bed Extension
Fig.2
Fig.3
Fig.4
Fig.5
ILP Liftgate Bumper Optional Configurations

ILP 25/33 Installation Manual
Rev. 1.4 - 11 -
5.2 Important Dimensions
Minimum Bed Height dimensions are ALWAYS MAXIMUM LOADED TRUCK.
Maximum Bed Height dimensions are ALWAYS DRY UNLOADED TRUCK.
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.
Ensure trailer/truck body does not interfere with installation or operation of the ILP liftgate series.
It is not recommended to cut, torch, or remove support materials from trailer/truck. Removing gussets,
stiffeners, light rings, or other such support structures may VOID your trailer/truck warranty.
Call technical support before starting the installation if any questions or concerns arise on mounting
dimensions or procedures.
Minimum clearance required for an ILP liftgate to install on a vehicle is 27” of clearance for 800mm
liftarms, and 31” of clearance for a 900mm liftarm. Clearance area should be free of any obstruction
that will prevent the installation of the liftgate, Fig.6.
800mm
Wooden Spacer
Chassis Frame
Body Long Rail
Floor
Crossmembers
31" (900mm Liftarms)
27" (800mm Liftarms)
Fig.6

ILP 25/33 Installation Manual
Rev. 1.4 - 12 -
6 Installation Dimensions
A= Bedheight: Top of trailer floor to level ground (with airbags up):........................................................................________
B =Top of floor to bottomof trailer cross member:.....................................................................................................________
C =Rear sill height (Top of floor tobottomof buck plate):If Stepped sill complete M,N; If Tapered sill complete O, P.
D = Crossmember height:...............................................................................................................................................________
.
E = Tire to end of vehicle body:......................................................................................................................................________
F = Bogie to end of vehicle body................................................________ Sliding Suspension? Yes________ No________
IfYescomplete 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 slider hole:.............................................................................................................................________
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:
Platform Size:
Platform Material:
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 = ________

ILP 25/33 Installation Manual
Rev. 1.4 - 13 -
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 bottomof 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: _________________________@______________________________

ILP 25/33 Installation Manual
Rev. 1.4 - 14 -
7 Platform Compatibility
Vehicle bed heights are absolute minimum for the corresponding platform
sizes when the vehicle is fully loaded and gassed.
800mm [31.50”] Liftarm
Vehicle
Bed
Height
Platform Sizes
48”x80”
54”x80”
52


51


50


49


48


47


46


45


44


43


42

n/a
41

n/a
40

n/a
39

n/a
38

n/a
n/a = not available
900mm [35.40”] Liftarm
Vehicle
Bed
Height
Platform Sizes
48”x80”
54”x80”
60”x80”
56



55



54



53



52



51



50



49



48



47




ILP 25/33 Installation Manual
Rev. 1.4 - 15 -
8 Chassis and Body Preparation - 800mm [31.50“] Liftarm
-Decrease ground clearance only to clear obstructions (i.e. fuel tanks, cross members, hitches, etc.)
WITHOUT EXCEEDING MAXIMUM “F” dimension of 26”.
-Minimum bed height is when truck/trailer is loaded to Maximum GVW (Gross Vehicle Weight).
- “F” dimension: Mount and Ground clearance always relate to each other on a set floor height. If the
“F” dimension is increased for a shorter mount clearance, the ground clearance will decrease.
1) Bed Height: Bed Height Ranges: Max=Unloaded / Min=Loaded Truck Measure from TOP of body floor
to ground. Vehicle must be on a flat leveled surface when measuring.
2) “F” Dim (Mount Frame Height): Measure from top of Mount Frame to top of body floor.
3) “K” Dim Ref. (Mount Clearance): Measure from rear of body to front edge of Mount Plates.
4) “G” Dim (Ground Clearance): Measure from bottom of Mount Frame to ground.
5) “A” Dim (Vehicle Body Cutout): Measure from the rear of the sill towards the front of the vehicle.
6) “B” Dim (Vehicle Body Cutout): Measure from top of the sill down to the ground.
7) 800mm [31.50”] Liftarm: Measure from center to center of pivot pins.
"K"
Mount Clearance
(Reference)
"F" Dim.
Bed Height
Max. 52"
Min. 38"
"G"
Ground
Clearance
"A"
"B"
Mount
Frame
Sill
Cutout
4"
4"
12"
G Dim = Bed Height –F Dim. –Mount Frame Height
Never exceed any of the dimensions from the table when installing the liftgate.
*Vehicle bed heights tend to lower 3”-4” when loaded.
Mounting Dimension Table
Mounting Dimensions for
800mm [31.50“] Liftarm
Chassis Frame
Cutout Dimensions
Bed Height
(Landen)
F
Dim.
G
Dim.
K
Dim.
A
Dim.
B
Dim.
52“-47“
26“
22“-17“
27“
19“
17“
47“-43“
23“
20“-16“
30“
20“
13“
43“-38“
20“
19“-14“
32“
18“
9“

ILP 25/33 Installation Manual
Rev. 1.4 - 16 -
9 Chassis and Body Preparation - 900mm [35.40“] Liftarm
-Decrease ground clearance only to clear obstructions (i.e. fuel tanks, cross members, hitches, etc.)
WITHOUT EXCEEDING MAXIMUM “F” dimension of 28”.
-Minimum bed height is when truck/trailer is loaded to Maximum GVW (Gross Vehicle Weight).
- “F” dimension: Mount and Ground clearance always relate to each other on a set floor height. If the
“F” dimension is increased for a shorter mount clearance, the ground clearance will decrease.
1) Bed Height: Bed Height Ranges: Max=Unloaded / Min=Loaded Truck Measure from TOP of body floor
to ground. Vehicle must be on a flat leveled surface when measuring.
2) “F” Dim (Mount Frame Height): Measure from top of Mount Frame to top of body floor.
3) “K” Dim Ref. (Mount Clearance): Measure from rear of body to front edge of Mount Plates.
4) “G” Dim (Ground Clearance): Measure from bottom of Mount Frame to ground.
5) “A” Dim (Vehicle Body Cutout): Measure from the rear of the sill towards the front of the vehicle.
6) “B” Dim (Vehicle Body Cutout): Measure from top of the sill down to the ground.
7) 900mm [35.40”] Liftarm: Measure from center to center of pivot pins.
"K"
Mount
Clearance
(Reference)
"F" Dim.
Bed Height
Max. 56"
Min. 47"
"G"
Ground
Clearance
"A"
"B"
Mount
Frame
Sill
Cutout
4"
4"
12"
G Dim = Bed Height –F Dim. –Mount Frame Height
Never exceed any of the dimensions from the table when installing the liftgate.
*Vehicle bed heights tend to lower 3”-4” when loaded.
Mounting Dimension Table
Mounting Dimensions for
900mm [35.40“] Liftarm
Chassis Frame
Cutout Dimensions
Bed Height
(Landen)
F
Dim.
G
Dim.
K
Dim.
A
Dim.
B
Dim.
56“-52“
28“
24“-20“
31“
21“
18“
52“-47“*
26“
22“-17“
32“
22“
15“

ILP 25/33 Installation Manual
Rev. 1.4 - 17 -
10 Gate Installation
10.1 Sill Cutouts
To prevent interference with the platform the vehicles sill could require notching.
Options
Sill Height
Action
4”
No sill notching required.
5”
If not notched, platform will be offset down approximately 1”-2” from bed extension.
Over 5”
Notch sill as show in Fig.7. Notches will require reinforcement, Fig.8
Rear View of Trailer
4.25"
Sill Height
38.75"
20.00"
Formed Steel Plate
Reinforcement
2X
1/8"
Sill Notch
Formed
Flatbar
20.00"
Sill Notches
Reinforce all sill cutouts with flatbar, Fig.8
Fig.7

ILP 25/33 Installation Manual
Rev. 1.4 - 18 -
11 Bed Extension Installation
11.1 Bed Extension (Weld-On)
1. Mark the center of the vehicle body and the bed extension. Clamp the bed extension to the forklift
forks, Fig.9. Maintain the bed extension centered and flush to the sill vertically and horizontally. Check
for squareness before continuing.
Wooden Spacer
Frame
Body Long Rail
Floor
Wooden Spacer
Frame
Body Long Rail
Floor
Forklift Forks
Forklifts Forks
Flush w/Sill
Bed
Extension
Sill
90°
Fig.9

ILP 25/33 Installation Manual
Rev. 1.4 - 19 -
If using a hoist, make a hole on the edge of a 3” standard channel, Fig.10. Clamp the channels to the bed
extension and attached the hoist to the 3” channels. Maintain the bed extension centered and flush to the
sill vertically and horizontally. Check for squareness before continuing.
Wooden Spacer
Frame
Body Long Rail
Floor
3" Channels
Flush w/Sill
Bed
Extension
Hoist
90°
Fig.10

ILP 25/33 Installation Manual
Rev. 1.4 - 20 -
2.Weld 3/16” x 5” welds on each end on the bed extension. Keep 1” gap clearance on corner post seam
line, Fig.11. All other welds shall be 3/16” x 2” centered on each rib, top and bottom of bed extension,
Fig.12. Bed extension shall be flush with floor level, Fig.13.
Top of Bed Extension
WeldingAreas
Bed Extension
1" No Weld Gap
Centered on
SeamLine
Corner
Post
5"
SeamLine
(Where sill
meets corner
post)
2" Centered
on Ribs
3/16"
3/16"
2"
C
L
10X
2X
Fig.11
Fig.12