Palfinger ILSL 33/44 User manual

ILSL 33/44
OWNERS MANUAL
11/14

ILSL 33/44 Owner‘s Manual
Rev.1.1 2
ILSL 33/44 Owners Manual
Document Part Number: 90-1614-002
ECN-0464, Rev. 1.1, 11-26-14
Copyright © 2014 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
Parts Order
[email protected]
Technical Support
[email protected]
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]

ILSL 33/44 Owner‘s Manual
Rev.1.1 3
Table of Contents
1 Important Notes........................................................................................................................5
1.1 Attention .......................................................................................................................5
1.2 Important Notes ............................................................................................................5
1.3 General Information ......................................................................................................6
2 Safety Information ....................................................................................................................8
3 General View of Liftgate...........................................................................................................9
3.1 ILSL Liftgate Overview..................................................................................................9
4 Maximum Load and Placing of Load on Platform .................................................................. 10
5 Operation of Liftgate ................................................................................................................12
5.1 Operation by Control Box/Hand Control ........................................................................12
5.2 Operation by Foot Control (Optional) ............................................................................ 15
5.3 Toggle Switch/Switches (Optional)................................................................................15
5.4 3-Button Flush Mount Control (Optional)....................................................................... 16
5.5 3-Button Flush Mount Control, Side Mount (Optional) ...................................................17
6 Preventive Maintenance and Quick Check .............................................................................18
6.1 Maintenance and Care..................................................................................................18
6.2 Lubrication ....................................................................................................................19
6.3 Checking and Changing the Oil.....................................................................................20
6.3.1 Recommended Hydraulic Fluids...................................................................... 20
6.4 Decal Placement and Inspection...................................................................................22
6.5 Quick Check List...........................................................................................................24
7 Troubleshooting .......................................................................................................................25
7.1 Liftgate will not power on...............................................................................................25
7.2 ON/OFF switch is ON but all functions are dead ........................................................... 28
7.3 Electrical Wiring ............................................................................................................29
7.4 Cross Test on Single Pole Plug Charge System ...........................................................33
7.5 Electrical Schematic......................................................................................................34
7.6 Control Board Connector Overview............................................................................... 35
7.7 Hydraulic Schematics....................................................................................................36
7.7.1 Hydraulic Schematic........................................................................................36
7.7.2 Slide Out Function...........................................................................................37
7.7.3 Lower Down ....................................................................................................37

ILSL 33/44 Owner‘s Manual
Rev.1.1 4
7.7.4 Lift Up Function ...............................................................................................37
7.7.5 Slide In Function..............................................................................................37
7.8 Hydraulic Schematic (Discontinued)..............................................................................38
7.8.1 Slide Out Function...........................................................................................39
7.8.2 Lower Down ....................................................................................................39
7.8.3 Lift Up Function ...............................................................................................39
7.8.4 Slide In Function..............................................................................................39
7.8.5 Push-Pull Valving (Discontinued) ....................................................................40
8 Needed Information for Ordering Spare Parts and Repairs................................................... 41
8.1 Ordering Spare Parts ....................................................................................................41
8.2 Repairs .........................................................................................................................41
9 Warranty.................................................................................................................................... 41
10 Contact Address.......................................................................................................................42

ILSL 33/44 Owner‘s Manual
Rev.1.1 5
1 Important Notes
1.1 Attention
Before starting any operations of the liftgate, please read and understand this OWNER’S MANUAL. It is
intended to act as a guide for the operation personal as well as to give help with preventive maintenance
but does not take place of unauthorized usage or repair by unqualified personnel.
Please contact your nearest PALFINGER Liftgates distributor or PALFINGER Liftgates in California or New
Jersey for assistance if you have questions regarding installation, operation or maintenance.
This owner’s manual applies to the following models: ILSL 33, 44
This is the safety alert symbol. It is used to alert you to potential personal injury hazards. Obey
all safety messages that follow this symbol to avoid possible injury.
1.2 Important Notes
The PALFINGER Liftgates ILSL model is an electro-hydraulically driven lift gate, designed to be stored
underneath the trailer for ultimate dock loading as well as offering up to 6-1/2 feet platform.
The Hydraulic Power Unit (HPU) is easily accessible for service and exchange.
The platform folded in half is supported by two torsion springs, each on one side, one support folding the
other unfolding operation. Lifting actions are carried out by hydraulic cylinders mounted on the lift arms.
The gate is equipped with swing fixtures mounted to the bottom on each lift cylinder. This enables the
platform to lower down the tip towards the ground. The hydraulic cylinders are equipped with solenoid
operated valves located at the port of each cylinder which prevents the platform from lowering accidently
unless the operator is activating the controls. This system also enables you to store the lift gate without a
separate platform latch.
The piston rods are treated against corrosion. The HPU is equipped with a built-in pressure relief valve,
which prevents overloading when lifting.
The valves do not prevent overloading of the platform when lowering or tilting down.
The electric supply is taken from the auxiliary batteries. The electric control power is protected via a 20 Amp
fuse and an on-off switch. Trailer application has an on-off switch located in the lockable control box. The
liftgate is operated from an outside control box which is located on the curbside of body. Foot controls are
optional, which enables the operator to handle the cargo and operate the liftgate by foot. A variety of
different product options can be purchased with the liftgate as well.

ILSL 33/44 Owner‘s Manual
Rev.1.1 6
1.3 General Information
REMEMBER!
It is the fleet manager’s responsibility to educate the operator on the liftgate and its intended use. The
operator’s attention should be drawn to the permitted load limits and an understanding of the operation to
ensure the safety throughout the operation.
ONE-MAN OPERATION!
Never let an “outsider” operate the liftgate while you are handling the cargo. A “misunderstanding” can
result in serious personal injury or even death.
In the interest of safety it is important that all operating personnel properly understand the functions
of the liftgate, possible hazards, dangers, the load limits and load positioning for that specific unit.
IMPORTANT NOTICE!
Before the operator uses the liftgate, they should be thoroughly familiar with the lift’s functions and
usage according to the following:
1. Improper operation of this lift can result in serious personal injury. Do not operate unless you have
been properly instructed, have read and are familiar with the operation instructions. If you do not
have a copy of the instructions please obtain them from your employer, distributor or lessor, as
appropriate, before you attempt to operate the lift.
2. Be certain the vehicle is properly and securely stopped before using the lift.
3. Always maintain the liftgate and inspect it for damage before usage. If there are signs of improper
maintenance, damage to vital parts, or slippery platform surface, do not use the lift. Do not attempt
your own repairs unless you are specifically trained.
4. Do not overload. See the Rating Label on the unit for the rated load. Remember that this limit
applies to both raising and lowering operations.
5. Each load should be placed in a stable position as near as possible to the body of the trailer.
6. Never stand in, move through or allow anyone else to stand in or move through the area in which the
lift operates, including that area in which a load might fall.
7. This is not a passenger lift. Do not ride the lift with unstable loads or in such a manner that a failure
would endanger you. The lift is not equipped with a back-up system to prevent falling cargo in the
event of a failure.

ILSL 33/44 Owner‘s Manual
Rev.1.1 7
The maximum loads must be observed and followed!
IMPROPER USE
It is not permitted to use the tail lift:
•As an elevating work platform.
•To push loads.
•To carry people (Only the operator may travel on the platform).
•To clear snow.
Please read through the operational and technical description of the PALFINGER Liftgates Liftgate.
Company Information:
Company Name:
Advisor Name:
Trailer Year Make & Model:
Liftgate Information:
Liftgate Serial Number:
Liftgate Model Number:
Date of Purchase:
Date of Installation:

ILSL 33/44 Owner‘s Manual
Rev.1.1 8
2 Safety Information
This manual follows the Guidelines set forth in ANSI X535.4-2007 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 we use it to alert you 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 we use it to alert you to special instructions, steps, or procedures.)
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. We have
designed this manual to illustrate the steps needed for the basic operation of this ILSL liftgate. It also
provides safety information and simple preventive maintenance tips.

ILSL 33/44 Owner‘s Manual
Rev.1.1 9
3 General View of Liftgate
3.1 ILSL Liftgate Overview
Steel Main
Aluminum Tip
Platform
Sub-Frame Mount
Assembly w/ Rails
Hyrdraulic
Pump
Box
Mount
Tube
Liftarm
Parallel
Arm
Battery
Box
ILSL Liftgate Overview

ILSL 33/44 Owner‘s Manual
Rev.1.1 10
Load diagram
10
20
30
40
50
60
70
80
90
100
0 12 24 36 48 60 72 84
distance from body (inch)
capacity (%)
4 Maximum Load and Placing of Load on Platform
Every Palfinger liftgate is rated up to a maximum load. The point of maximum load is rated at a defined
distance. The center point of maximum load is at 24” from the outside of the trailer body to center of load.
Trailer
Body
Load
24"
Center Point of Load
By increasing this distance the maximum load of the lift gate is decreasing.
An overview about the rating depending, on the distance from the end of the platform is shown in the
following load diagram.
Load Diagram
Capacity:
100% at 24”
65% at 36”
45% at 48”
30% at 60”

ILSL 33/44 Owner‘s Manual
Rev.1.1 11
NOTES

ILSL 33/44 Owner‘s Manual
Rev.1.1 12
5 Operation of Liftgate
5.1 Operation by Control Box/Hand Control
NOTE: Never slide platform in or out with load on the platform
1. Power the liftgate by turning the ON/OFF switch down.
On/Off Switch
Lift
Slide
In
Out
Up
Down
For questions regarding operation call (888) 774- 844
ILSL
• To operate this liftgate read and understand the
operating decals and manuals.
• Make certain the platform is clear before
operating the lift.
• Liftgate shut-off switch must be turned off when
liftgate is not in use.
• Keep platform in horizontal position when
loading and unloading.
• Do not overload, refer to capacity decals.
Loading Position:
• Lower platform
• Slide out liftgate
• Unfold platform
Storag e Position:
• In down position fold up platform tip
• Slide in liftgate
• Raise platform
Max Capacity
on Platform
Platform
Load
24"
2. Rotate the Lift button Down to lower the platform enought that it clears the platform storage
upstops.
Upstop
Up
Down
Slide
Lift
In
Out
3. Use the Slide button Out to slide the gate out from its stored position until it meets the stop bolt at
the front of the slide rail.
Stop Bolt
Up
Down
Slide
Lift
In
Out

ILSL 33/44 Owner‘s Manual
Rev.1.1 13
4. Use the Lift button Down to lower the platform to about 3“ off the ground. Unfold the platform tip
manually by using the straps. Use Lift button Down again to lower platform to the floor.
3"
Up
Down
Slide
Lift
In
Out
5. Load the platform. Center the load 24“ away from the outside of the trailer body.
Load
24"
6. At this point of operation, the operator must use the 2-Button Hand Held Remote (HHR) to lift the
platform/load up and down. Toggle switches and Foot Controls may also be used if these options
have been installed. If using the Toggle Switch or Foot Controls, see pages 13 for operating
instructions.
7. Press and hold the Top (white) button on the 2-Button Hand Held (HHR) Control to raise the
platform/cargo. Place the control on the holster while removing the cargo from the platform. Press
and hold the Bottom (black) button to lower the platform back to the ground. REMINDER: Do not
store HHR inside refrigerated bodies.
Up
Down

ILSL 33/44 Owner‘s Manual
Rev.1.1 14
To Store Liftgate
1. When platform is on the ground, use the Lift button Up to get the platform 3“ off from the ground.
Manually fold the tip of the platform
3"
Up
Down
Slide
Lift
In
Out
2. Use the Slide button In until the sliding plates hit the stop bolt in the rear of the sliding rail.
Stop Bolt
Up
Down
Slide
Lift
In
Out
3. When the sliding plates have stopped and reached the stop bolt in the rear, use the Lift button Up to
secure the platform flush with the upstops until the upstop is compress ½“ and release the button.
1/2" Compression
of Upstop
Up
Down
Slide
Lift

ILSL 33/44 Owner‘s Manual
Rev.1.1 15
5.2 Operation by Foot Control (Optional)
Lower Platform:
Step on the front foot control and hold, wait three seconds before stepping on the rear foot control.
Raise Platform:
Step on the rear foot control and hold, wait three seconds before stepping on the front foot control.
If the platform is not responding to the controls within three seconds, repeat steps above.
Front
Rear
Front Foot
Control
RearFoot
Control
Raise Platform
Lower Platform
Front Foot
Control
RearFoot
Control
5.3 Toggle Switch/Switches (Optional)
1. Toggles switches are an alternative to the 2-Button HHR Control.
2. Toggles switches only raise the platform up and down.
MBB MBB
UP DOWN

ILSL 33/44 Owner‘s Manual
Rev.1.1 16
5.4 3-Button Flush Mount Control, Vertical Mount (Optional)
Raise Platform
Push and hold Top button
Lower Platform
Push and hold the Bottom button
Slide In Platform
Push and hold the Top and Middle
buttons simultaneouly
Slide Out Platform
Push and hold the Botton and Middle
buttons simultaneouly

ILSL 33/44 Owner‘s Manual
Rev.1.1 17
5.5 3-Button Flush Mount Control, Horizontal Mount (Optional)
Raise Platform
Push and hold Top button
Lower Platform
Push and hold the Bottom button
Slide In Platform
Push and hold the Top and Middle
buttons simultaneouly
Slide Out Platform
Push and hold the Botton and Middle
buttons simultaneouly

ILSL 33/44 Owner‘s Manual
Rev.1.1 18
6 Preventive Maintenance and Quick Check
The ILSL needs preventive maintenance to perform at its fullest capability. Lubricate and inspect regularly.
Also, check on hoses, cables, controls, etc. and make sure these components are not damaged.
REPAIR OR REPLACE IMMEDIATELY FAULTY PARTS
6.1 Maintenance and Care
The following “inspection and maintenance” should be performed at the recommended intervals depending
on operation and amount of cycles or at the time when the unit shows any signs of damage or abuse. In
order to prolong the liftgates longevity it is important to maintain and perform preventive care as indicated
below.
* Recommended bases for
inspection and maintenance
Depending
on use Daily Monthly Quarterly
Cleaning x
General lubrication of pins and
bushings x
Oil level inspection x
Oil change x
Check hydraulic hoses and pipes for
leaks x
Check controls and connections x
Check pins and pin retaining bolts x
Check batteries and connections x
Check warning labels and other safety
equipment for effectiveness and
visibility
x
Visual check for loose or missing parts
and un-usual noise during operation x
Check lock bolts and pins for tightness x
Check complete function of gate x
Check mounting brackets of lift gate to
frame for cracks or damage visually x
Maintenance Schedule

ILSL 33/44 Owner‘s Manual
Rev.1.1 19
6.2 Lubrication
Properly lubricated, the ILSL series PALFINGER Liftgates will ensure longevity. Lubricate the liftgate at the
same time as the trailer. Grease more frequently if the liftgate is heavily used. The liftgate should be
greased every 500 cycles (depending on use – estimated every 3 month).
All bearing points must be lubricated in accordance with the maintenance intervals.
Reminder: Lubricate all points with the platform at ground level.
Oil reservoir
(Inside)
4 zerks:
- 1 Cylinder
- 1 Lift arm
- 1 Parallel arm
- 1 Swing fixture
3 zerks:
- 1 Cylinder
- 1 Lift arm
- 1 Parallel arm
4 zerks:
- 1 cylinder
- 1 Lift arm
- 1 Parallel arm
- 1 Swing fixture
3 zerks:
- 1 cylinder
- 1 Lift arm
- 1 Parallel arm
IN
OUT
IN
Grease – 12 places, (3 in the mount frame, 3 in the cylinder/platform area).
IN
OUT
Oil level in the power pack tank (see marking inside of power pack reservoir).
IN
Lubricate - Platform hinges and Cart Stops if present (use ZEP-45 spray for lubrication).
NOTE: Avoid using grease on rails to help prevent any mud and dirt build up.

ILSL 33/44 Owner‘s Manual
Rev.1.1 20
6.3 Checking and Changing the Oil
Check the quality of the hydraulic fluid, the fluid should be free of contaminants such as debris, sludge,
water, or air. All these factors can contribute to poor system performance and will reduce the life of the
liftgate and lifgate components. If the fluid appears to be in poor condition, take the following steps to
change the oil.
1.Lower gate to ground.
2.Remove the cover from the pump and motor box and locate the oil drainage bolt (6mm hex bolt)
located at the bottom of the tray and let the fluid drain out of the reservoir and into an approved
container. Screw the oil drainage bolt back.
3.Unscrew the oil filler cap. Use a good quality fluid based on your location; refer to the recommended
fluids table. The fluid level should be between marks 5 and 7 when the platform is at ground level.
4.Change oil at least once a year, preferably in the fall before the weather gets cold.
6.3.1 Recommended Hydraulic Fluids
TEMP. RANGE
BRAND
-10 TO 150 F EXXON UNIVIS J26
MOBIL OIL DTE 13M
CHEVRON AW MV32
ROSEMEAD MV 150 (32)
-50 TO 150 F MOBIL DTE 13M
SHELL AERO FLUID 4
EXTREME COLD TEMPERATURE:
USE MILITARY SPEC:
MIL H5606
Hydraulic
connections
Suction filter
in oil tank
Oil filler cap
S5 Shift valve
Motor Studs
Motor Solenoid
Pressure Gauge plug
Below valve block:
Oil drainage screw 6mm hexagon
Tray lock bolt