Palfinger ILP User manual

ILP
INSTALLATION MANUAL
& CHECK-OFF SHEET
ECN-M0247 Rev. 1.4, Date 07-03-2013 Part #90-0113-200
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

T ABLE OF CONTENT
Revision 1.3 - 2 -
T ABLE OF CONTENT
T ABLE OF CONTENT ...................................................................................................................................2
1 Safety Information ....................................................................................................................4
2 Gate Overview and Components............................................................................................. 5
3 General information: ................................................................................................................6
4 Installation Dimensions ...........................................................................................................8
4.1 Installation Dimensions 800mm arm ILP – SQUARE TUBE MAIN FRAME................... 9
4.1.1 Possible Mount Plate Modifications for Short Over Hang.................................9
4.2 Bed Height Ranges: Unloaded Truck 800mm Arm – SQUARE TUBE........................... 10
4.3 Installation Dimensions 800mm arm ILP – ROUND TUBE MAIN FRAME..................... 11
4.4 Bed Height Ranges: Unloaded Truck 800mm Arm........................................................12
4.5 Installation Dimensions 900mm arm ILP .......................................................................13
4.6 Bed Height Ranges: Unloaded Truck 900mm Arm........................................................14
5 Chassis and Body Preparation................................................................................................ 15
5.1 Bed Extension & Dock Bumper Installation ................................................................... 15
6 Gate and Platform Installation .................................................................................................16
6.1 Frame Installation .........................................................................................................16
6.2 Gate Installation Using Liftarm Pins (Platform Not Installed) ......................................... 18
6.2.1 Platform Installation.........................................................................................19
6.3 Tension on the spring ...................................................................................................20
7 Electrical Installation................................................................................................................21
7.1 Main Power Connections ..............................................................................................21
7.2 Circuit Breaker ..............................................................................................................21
7.3 UP/DOWN Switch Installation .......................................................................................22
7.3.1 Roll up door setup ...........................................................................................22
7.3.2 Swing Door setup............................................................................................23
7.4 ON/OFF Switch............................................................................................................. 24
7.5 Remote Hand Control Installation (Optional)................................................................. 24
7.6 Main power supply wiring..............................................................................................25
7.7 Electrical schematic of gate...........................................................................................26
8 Lubrication and Final Inspection............................................................................................. 27
8.1 Hydraulic Schematic and Decal Placement................................................................... 28
8.2 Decal Placement and Inspection...................................................................................29
9 Check Off Sheet........................................................................................................................ 31

T ABLE OF CONTENT
Revision 1.3 - 3 -
Recommended Tools For Installation
Metric Wrench Set
Test Light
½” Impact & Sockets
Small To Medium Bottle Jack
Pry Bar
Min. 250 Amp Welder
Basic Screwdrivers
Snap Ring Pliers
Sm. Metric Socket Set
Forklift or O/H Crane
3/8 Drill Motor
Cutting Torch or Equiv.
Pliers
Hammer
Assorted Drill Bits
Hand Held Grinder
Wire Crimp Pliers
Metric Allen Set 1.5mm-10mm
Floor Jack or Equiv.
Paint Gun
Heat Gun or Equiv.

Safety Information
Revision 1.3 - 4 -
1 Safety Information
This manual follows the Guidelines set forth in “ANSI Z535.4-2007” for alerting you to possible hazards and
their potential severity.
NOTICE without the safety alert symbol is used to address practices not related to personal injury.
(In this manual we use it to alert you to special instructions, steps, or procedures.)
CAUTION without the safety alert symbol is used to address practices not related to personal injury.
(In this manual we use it to alert you to potentially hazardous situation which, if not avoided, may result in
property damage.)
! CAUTION indicates a potentially hazardous situation which, if not avoided, may result in minor or moder-
ate injury.
! WARNING indicates potentially hazardous situation which, if not avoided, could result in death or serious
injury.
! DANGER indicates an imminently hazardous situation which, if not avoided, will result in death or serious
injury.

Gate Overview and Components
Revision 1.3 - 5 -
Lift Cylinders
Roller
Hydraulic Power Unit
Bed Extension
Platform
Mount Plates
Parallel Arm
Lift Arm
Mount Frame
Center of Gravity
2 Gate Overview and Components
Figure 1 Liftgate overview with component description
A liftgate contains three (3) main objectives:
1) Foldable platform with shackles and coil springs
2) Lift arm assembly with parallel arms and lift cylinder
3) Main frame with roll over assembly and power pack enclosure
Rubber
Snubber

General information:
Revision 1.3 - 6 -
3 General information:
1. Read Manual completely before beginning any work
2. Refer to your truck manufacturer’s instructions before adding any auxiliary equipment.
3. Pay Special attention to items marked with this symbol:
4. All welding should be performed by qualified personnel per AWS standards
5. Always Ground closest to your welding point to prevent arcing through moving parts
6. Contact PALFINGER Liftgates for Special Installations not covered in this Installation Manual
7. Do not paint cylinder shafts or nylon rollers (Use non-chlorinated brake cleaner to remove
over spray)
8. Verify that pin lock bolts are tight
9. Grease all pivot points
10. Verify that ALL decals are placed properly (Contact PALFINGER Liftgates to replace any missing
decals)
11. Final Check-Off-Sheet at rear of this manual MUST be filled out and kept in your records for
future reference.
12. 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
•Measure from top of body floor to ground. Vehicle must be on flat level ground when
measured.
2) MOUNT TUBE SETTING [F]
•Measure from TOP of Mount Tube to TOP of body floor
3) MOUNT TUBE CLEARANCE [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

General information:
Revision 1.3 - 7 -
Mounting Notes:
Read and clearly understand manual BEFORE beginning ANY work
Important!!!
The basic rule of PALFINGER Liftgates ILP 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.
oIf the sill is greater than what’s allowed, the sill has to be notched and capped to achieve
original strength.
•Bend flat bar and weld 100% around the notch.
•Minimum bed height dimensions are ALWAYS MAXIMUM LOADED TRUCK
•Floor Height Ranges: Max=Unloaded; 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 floor height
goes below minimum bed height when truck is loaded.
Call tech support before starting the installation if you have any questions or concerns
on mounting dimensions 888-774-58

Installation Dimensions
Revision 1.3 - 8 -
4 Installation Dimensions
Do not weld across the corner posts
No weld
areas
No weld
areas
Figure 2 Chassis Dimension sheet for special requests

Installation Dimensions
Revision 1.3 - 9 -
4.1 Installation Dimensions 800mm arm ILP – SQUARE TUBE MAIN FRAME
Ground Clearance
"F" Dim.
*Mount Clearance
End of Body to
Front of Mount Plate
Bed Height
Figure 3 Mounting dimensions 800mm arm
NEVER exceed any of the dimensions from the
table
*Use Mount Clearance for pre-install clearance issues
(i.e. spring hangers, fuel fills, C/M bolts, etc.)
Bed Height Ground
Clearance
„F“
Dimension
38 12 22
39 13 22
40 14 22
41 15 22
42 16 22
43 17 22
44 18 22
45 19 22
46 19 23
47 19 24
48 19 25
49 19 26
50 19 27
51 20 27
52 20 28
53 20 29
Mounting Dimensions
STAY WITH THE „F“ DIMENSION
Minimum bed height is when truck/trailer is loaded to MAX GVW
Mounting Dimensions
ILP with 800 mm (31.5”) arm, 48" (1200 mm) platform
Bed Height F-Dimension
Cut-out X
vertical
Cut-out Y
horizontal
Mount Clearance
(can be shortened by 5”)
Ground
Clearance
38 to 47.5 22 12 17.5 38.5 12 to 20
40 to 48.5 23 14 16.5 37.5 13 to 20
42 to 50 25 15.5 15 35 13 to 20
44 to 52.5 27 17.5 13.5 33 13 to 20
46 to 53 29 19.5 12.5 32 13 to 20
•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.
Decrease ground clearance minimally only to clear obstructions (i.e. fuel tanks, cross members, hitches,
etc.) WITHOUT exceeding MAXIMUM “F” dimension (29”)
4.1.1 Possible Mount Plate Modifications for Short Over Hang
For installations on trucks with short over hang.
Cut plate in front and reweld it at the back with1/4"weld,
this will shorten the mount frame clearance by 6'
1/4" weld
10-3/4"
18-7/8"
Figure 4 Mount plate modification for short overhang

Installation Dimensions
Revision 1.3 - 10 -
4.2 Bed Height Ranges: Unloaded Truck 800mm Arm – SQUARE TUBE
2"x3"x3/16" Angle
1/4"x3" HR Flat
Frame Cap
Refer to chapter 3
Not Supplied
Not Supplied
38"
12"
17-1/2"
12"
12"
16-1/2"
800 mm
15"
12"
15-1/2"
12"
19-1/2"
Min laden
bed height
Max
bedheight
43-1/2"
53"
51"
47-1/2"
31-1/2"
Basic frame cut out and installation information ILP, (800 mm) 48" P/F
Bedheights covered: 38", 43", 47", 51" and 53"
Assuming 22" F-Dim Assuming 23" F-Dim
Assuming 27" F-Dim
Assuming 25" F-Dim
Assuming 29" F-Dim
12"
14"
17-1/2"
13-1/2"
12-1/2"
Figure 5 Frame cap suggestions related to bed height 800mm

Installation Dimensions
Revision 1.3 - 11 -
4.3 Installation Dimensions 800mm arm ILP – ROUND TUBE MAIN FRAME
Ground Clearance
"F" Dim.
*Mount Clearance
End of Body to
Front of Mount
Plate
Figure 6 Mounting dimensions 800mm arm
NEVER exceed any of the dimensions from the
table
*Use Mount Clearance for pre-install clearance issues
(i.e. spring hangers, fuel fills, C/M bolts, etc.)
Bed Height Ground
Clearance
„F“
Dimension
38 12 22
39 13 22
40 14 22
41 15 22
42 16 22
43 17 22
44 18 22
45 19 22
46 19 23
47 19 24
48 19 25
49 19 26
50 19 27
51 20 27
52 20 28
53 20 29
Mounting Dimensions
STAY WITH THE „F“ DIMENSION
Minimum bed height is when truck/trailer is loaded to MAX GVW
Mounting Dimensions
ILP with 800 mm (31.5”) arm, 48" (1200 mm) platform
Bed Height F-Dimension
Cut-out X
vertical
Cut-out Y
horizontal
Mount Clearance Ground
Clearance
38 to 47.5 22 12 17.5 38.5 12 to 20
40 to 48.5 23 14 16.5 37.5 13 to 20
42 to 50 25 15.5 15 35 13 to 20
44 to 52.5 27 17.5 13.5 33 13 to 20
46 to 53 29 19.5 12.5 32 13 to 20
•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.
Decrease ground clearance minimally only to clear obstructions (i.e. fuel tanks, cross members, hitches,
etc.) WITHOUT exceeding MAXIMUM “F” dimension (29”)

Installation Dimensions
Revision 1.3 - 12 -
4.4 Bed Height Ranges: Unloaded Truck 800mm Arm
2"x3"x3/16" Angle
1/4"x3" HR Flat
Frame Cap
Not Supplied
Not Supplied
38"
12"
17-1/2"
12"
12"
16-1/2"
13-1/2"
800 mm
15"
12"
15-1/2"
13"
12"
19-1/2"
Min laden
bed height
Max
bedheight
43-1/2"
53"
51"
47-1/2"
31-1/2"
Basic frame cut out and installation information ILP - ROUND TUBE
Bedheights covered: 38", 43", 47", 51" and 53"
Assuming 22" F-Dim Assuming 23" F-Dim
Assuming 27" F-Dim
Assuming 25" F-Dim
Assuming 29" F-Dim
12"
14-1/2"
15-1/2"
Figure 7 Frame cap suggestions related to bed height

Installation Dimensions
Revision 1.3 - 13 -
4.5 Installation Dimensions 900mm arm ILP
Decrease ground clearance minimally only to clear obstructions (i.e. fuel tanks, cross
members, hitches, etc.) WITHOUT exceeding MAXIMUM “F” dimension (29.5”)
Suggested Mounting Dimensions
Ground Clearance
"F" Dim.
*Mount Clearance
End of Body to
Front of Mount Plate
Bed Height
Figure 8 Mounting dimensions 900mm arm
NEVER exceed any of the dimensions below
*Use Mount Clearance for pre-install clearance issues
(i.e. spring hangers, fuel fills, C/M bolts, etc.)
Bed
Height
Ground
Clearance
„F“
Dimension
45 15 26
46 16 26
47 17 26
48 18 26
49 19 26
50 20 26
51 20 27
52 20 27.5
53 21 27.5
54 21 29
55 21.5 29.5
Minimum-Maximum Dimensions Suggested Mounting Dimensions
Minimum bed height is when truck/trailer is loaded to MAX GVW (all dimensions in inches)
Mounting Dimensions
ILP 54” (1375 mm) and 60" (1525 mm) platform with 900mm arm
Bed Height F-Dimension Cut-out X
vertical
Cut-out Y
horizontal
Mount Clearance
(can be shortened by 5”)
Ground
Clearance
45 to 50 26 17 20 41 15-20
45 to 53 27.5 17.5 19.5 39 17.5-21.5
54 to 55 29.5 19.5 18.5 37 20.5 to 21.5
•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 de-
crease.

Installation Dimensions
Revision 1.3 - 14 -
4.6 Bed Height Ranges: Unloaded Truck 900mm Arm
Assuming 26" F-Dim Assuming 27" F-Dim
Assuming 29" F-Dim
Basic frame cut out and installation information
ILP 900 mm Arm (35") 54"Platform
Bed heights covered: 45", 47", 51" and 55"
Use the closest to your application
These dimensions are starting points. Your final dimensions may vary
depending on actual installation F-Dim
Refer to chapter 3 and 4
Assuming 28" F-Dim
12"
12"
12"
(900 mm)
35-1/2"
2"x3"x3/16" Angle
1/4"x3" HR Flat
Frame Cap
Not Supplied
Not Supplied
15-3/4" 22-1/4"
17"
21-1/2"
12"
18-1-4"
21"
19-1/2"
20-1/2"
Cut-out vertical
Cut-out horizontal
Figure 9 Frame Cap suggestions related to bed height 900mm

5 Chassis and Body Preparation
Revision 1.3 - 15 -
5 Chassis and Body Preparation
The ILP liftgate will require different mounting space requirements depending on floor heights.
1. Determine the correct frame cut out according to your specific bed height refer to Chapter
4.2 and 4.4.
2. With long overhang it is even more important to maintain MIN F-Dim and MAX ground
clearance.
3. Trim rear of truck frame per above picture.
5.1 Bed Extension & Dock Bumper Installation
Tack Weld Or ClampTo Rear Sill
Tack or clamp channel to hold in place
Do NOT weld along vertical posts on van install.
3/16" welds for bed extension
Floor at Back & Front Edge
Bed Extension Must Be Flush With
Channel or Equiv.
3" Channel
"A"
Channels Shipped with 45°angle on each side
"A"
"A"
Bed Height Bumper
44" and Above 24"
43" and Below 20"
Note:
20" Bumpers Have Single Step
Interlift 12" Bumpers might
need notching in some cases
3/16"
3/16"
3/16"
12"
12"
Figure 10 Bed extension install Figure 11 Dock bumper install
1. Tack weld channels or angle (2) to rear sill (not supplied) only temporarily, if possible use
clamps
2. Center bed extension, flush with floor. (Figure 10) .
3. Clamp or tack weld to channels or angle
4. Verify bed extension is centered on body and flush at the sides
5. Weld as shown in Figure 12 from the top and the bottom
-> 3/16” x 4” welds on approximately 10” centers alternate top and bottom welds
Figure 12 Bed extension weld areas
6. Install dock bumpers (if applicable) (available from PALFINGER Liftgates as an option)
7. If installing dock bumpers refer to Figure 9
Welds

6 Gate and Platform Installation
Revision 1.3 - 16 -
6 Gate and Platform Installation
6.1 Frame Installation
Never work under platform without safety supports
1. Unfold platform and clamp forklift forks, overhead crane or equivalent to platform
2. Raise lift gate by using forklift, overhead crane or equivalent and align front edge of platform to back
edge of bed extension leaving approx. 3/16 gap. Place it against the temporary channel, flush with
the body.
3. Use floor jack or equiv. to swing frame assembly up to proper “F” dimension per Figure 13.
4. Use second jack or pry bar at roll over wheel bracket to set horizontal rollover wheel bracket.
a. 12 V power supply needed for release pressure on lift cylinders valves, if necessary.
5. Verify that the 2 factory tack welds on each side at the lower knuckles are secure.
6. Set mount plates in place and tack weld using 3 fillet welds - 2” long on each side of mount plate and
on top of mount plate. Make sure to connect BODY LONG RAIL to mount plate, if necessary extend
mount plate with flat bar to reach BODY LONG RAIL. The mount plate should be flat on the channel.
7. Connect 2 Ga. battery cable to truck battery, aux battery or temporary battery
(Ref. 7 Electrical Installation)
8. Turn on On/Off switch. Completely cycle gate to assure proper alignment and functions
9. If it works remove factory tack welds from lower lift cylinder knuckle (Fig. 12)
10. Check if wires and hoses are not in the liftgate operational areas during moving at the platform.
Min. 8" Weld Overlap
1/4"
Use second jack to level
Underride Guard(ILFS)/
Rollover Wheel(ILP)
12 volt power may need to be
connected to release
pressure from Lift Cylinders
(Down Function)
Figure 13: Lift table and jack support

6 Gate and Platform Installation
Revision 1.3 - 17 -
PLATFORM WILL NOT TILT TO THE GROUND IF THESE WELDS ARE NOT REMOVED!
Operator must continue to hold down button/toggle after lift arms touch ground to allow platform tip
to tilt to the ground
Figure 14 Removing of swing fixture tack welds
11. Slide out upper parallel arm pin just enough to rotate coils springs into position for platform spring
assist per Figure 18.
- Do not power gate hard against bed extension while gate is only tack welded in position
12. Complete welding of gate. Weld all contact areas 100% with ¼” fillet or butt welds.
13. Adjust sliding bumper temporarily with a clamp so the platform is approximately 5 to 10 degree in
from vertical when resting against the wheel. Weld bumper with 3/16" weld 100%. (Fig. 12)
Figure 15 Platform roll over wheel adjustment Figure 16 Frame captioning for tight storage of liftgate
14. Verify platform lowers without hanging up on wheel before welding. Slide wheel in slightly until
platform lowers smoothly
15. Install frame caps per chapter 4.2 or 4.6. (See Fig. 14 alternate frame modification)
16. Adjust (2) rubber snubbers up to force platform against frame caps to hold platform from bouncing
while vehicle is moving (See Fig. 1)
17. Check all contact areas if they are welded and polish them. There should not be any sharp corners
Grind off tack welds from both
knuckles (these are the only ones
which are not painted)
Knuckle is able to swing when platform
touches ground with tacks removed
Remove tack welds and slide
to achieve 5°-10°.
Verify platform will lower without
hang up before welding. Slide
tube slightly if platform does not
lower smoothly
5°-10°
Angle serves to hold body and
truck frame together as the
gate is very strong

6 Gate and Platform Installation
Revision 1.3 - 18 -
Use alternative platform store stop method on installation with square cut frames.
Set channel to contact
platform when closed. Adjust
(2) rubber snubbers to raise
tight against channel
3" Std channel
Weld to chassis
and/or
long sill
Figure 17 Alternative frame modification
•Raise tip of platform to achieve 1 1/2“ – 2“ incline (loosen clamps if necessary)
Figure 18 Platform shim to incline angle at bed level
To achieve the incline of the platform add shim’s to shackle profile
6.2 Gate Installation Using Liftarm Pins (Platform Not Installed )
1. Place lift gate WITHOUT platform securely on rolling cart or equivalent.
2. Slide gate on cart underneath vehicle
3. Lift mount frame assembly until upper lift arm bushings are able to align with mount holes
in bed extension gussets
4. Slide upper lift arm pins through bed extension holes and lift arms
5. Using floor jack or equiv. to swing frame assembly up to proper “F” dimension.
6. Use second jack to level out rollover wheel, if necessary.
7. Verify that the 2 factory tack welds at the lower swing shackles are secure. (see Figure 6.7)
8. Install mount plates and tack weld using 2 fillet welds 2” long on each side and top of mount plate to
frame and at mount plate to mount frame location

6 Gate and Platform Installation
Revision 1.3 - 19 -
6.2.1 Platform Installation
Never work under platform without safety supports
1. Support gate frame assembly on proper size and capacity horses or equiv.
2. Slide pins out to clear lift arm clevis (closest to center of platform)
3. Do not slide so far that triangle block or spring fall out
4. Lift platform to lift arms with forklift or equiv.
5. Rotate coil spring away from 8x80mm bolt, so there is no tension during gate installation
6. Align lift arms into clevises and drive pin until pin tab seats in pin tab hole and install pin bolt and
tighten to 14 ft-lbs
Short leg against tab
Curb Side LOOKING Rear
Liftarm Clevis
Triangle Block
Figure 19 Platfrom spring installation
Figure 20 Platform coil spring install

6 Gate and Platform Installation
Revision 1.3 - 20 -
6.3 Tension on the spring
The torsion springs that assist the folding of the gate are shipped with no tension to aid the installation
process.
a. The dashed lines in Figure 18 show the shipping position of the spring arm.
b. Fold up the platform and lower down the gate to the ground.
c. Flip over the platform into stored position ATTENTION, platform is heavy!!!!
d. Partially remove the parallel arm pin as shown and reorient the spring. Slide the pin back
and tighten up lock nut.
e. Fold and unfold the platform and feel the assistance of the spring. If it is still too heavy add
weld to the block until force is at 35ft- lbs