Palfinger ILU 40 User manual

ILU
INSTALLATION MANUAL
& CHECK-OFF SHEET
ECN-M0257 Rev. 1.5, Date 07-15-2013 Part #90-1313-200
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 CONTENTS
Revision 1.5 - 2 -
T ABLE OF CONTENTS
T ABLE OF CONTENTS .................................................................................................................................2
1 Safety Infromation ....................................................................................................................5
2 Important Notes:.......................................................................................................................6
3 Chassis Dimension Sheets......................................................................................................8
4 Installation Dimensions ...........................................................................................................9
4.1 General Bed Height Ranges for ILU liftgates................................................................. 10
4.2 Chassis and Body Preparation...................................................................................... 11
4.2.1 Mount frame clearance....................................................................................11
4.2.2 Rear sill preparation ........................................................................................12
5 Gate Installation........................................................................................................................14
5.1 Slide rail bracket installation.......................................................................................... 14
5.2 Liftgate attachment .......................................................................................................15
5.3 Control power wiring setup............................................................................................16
5.4 Platform installation.......................................................................................................17
5.4.1.1 Swing-door platform modifications .....................................................17
5.5 Lift arm Up-stop installation and rail stops setup ........................................................... 18
5.6 Control box installation..................................................................................................19
6 Gate adjusting and detailing....................................................................................................20
6.1 Setting B-13 lift arm sensor...........................................................................................20
6.2 Setting B-15 Platform sensor ........................................................................................21
6.3 Platform adjusting with bolts .........................................................................................22
7 Electrical Installation................................................................................................................23
7.1 Breaker Installation .......................................................................................................23
7.2 Wiring schematic main battery power - Truck setup......................................................24
7.3 Wiring schematic main battery power - Trailer setup..................................................... 25
7.4 Trail charger installation................................................................................................26
7.5 On/off switch installation ...............................................................................................27
7.5.1 Truck setup .....................................................................................................27
7.5.2 Trailer setup ....................................................................................................27
7.6 Control board wiring and connector setup..................................................................... 28
7.7 Control board plug setup...............................................................................................29
7.8 Control box wiring (internal) ..........................................................................................30
7.9 2 Button Remote Hand Control .....................................................................................30
8 Hydraulic schematic.................................................................................................................31
8.1 Lubrication ....................................................................................................................32
9 Decal Placement.......................................................................................................................33

T ABLE OF CONTENTS
Revision 1.5 - 3 -
T ABLE OF FIGURES
Figure 1 Trailer dimension sheet .................................................................................................................8
Figure 2 Truck dimension sheet ..................................................................................................................8
Figure 3 Installation Drawing - provided by PALFINGER Liftgates engineering department ........................9
Figure 4 Mounting clearance .....................................................................................................................11
Figure 5 Sill cut-out dimensions - rear view ...............................................................................................12
Figure 6 Sill cut-out – sideview..................................................................................................................12
Figure 7 Slide rail installation.....................................................................................................................14
Figure 8 Liftgate installation to previous installed rails ...............................................................................15
Figure 9 platform attachment.....................................................................................................................15
Figure 10 Board control power wiring connection ......................................................................................16
Figure 11 Main Power supply setup ..........................................................................................................16
Figure 12 Platform installation and wiring ..................................................................................................17
Figure 13 Installation of up-stops...............................................................................................................18
Figure 14 Mount plate slide stops..............................................................................................................18
Figure 15 Control box placement...............................................................................................................19
Figure 16 B-13 lift arm adjustment.............................................................................................................20
Figure 17 B-15 adjustment on platform .....................................................................................................21
Figure 18 Platform wiring with B-15 and controls.......................................................................................21
Figure 19 Circuit breaker installation .........................................................................................................23
Figure 20 Main wiring - truck setup............................................................................................................24
Figure 21 Main wiring - trailer setup - dual pole charging system ..............................................................25
Figure 22 Main wiring - trailer setup - single pole charging system............................................................25
Figure 23 Trail charger wiring....................................................................................................................26
Figure 24 Cab Cut-off switch connection...................................................................................................27
Figure 25 On-Off setup trailer....................................................................................................................27
Figure 26 Control board wiring schematic .................................................................................................28
Figure 27 Plug setup on PC - Board..........................................................................................................29
Figure 28 Control box wiring schematic.....................................................................................................30
Figure 29 Hydraulic schematic ILU............................................................................................................31
Figure 30 Grease and Lubrication points...................................................................................................32

T ABLE OF CONTENTS
Revision 1.5 - 4 -
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 Grease Gun Heat Gun or Equiv.
Min. 250 Amp Welder Cutting Torch or Equiv.

1 Safety Infromation
Revision 1.5 - 5 -
Safety Infromation 1
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 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.)

2 Important Notes:
Revision 1.5 - 6 -
Important Notes: 2
1. Read Manual completely before beginning any work
2. Refer to your truck manufacture’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 Bed Height Ranges: Max=Unloaded / Min=Loaded Truck
- Measure from top of body floor to ground. Vehicle must be on flat level ground
2) MOUNT FRAME CLEARANCE
- Measure from BACK of truck/trailer to spring/tire or air suspension components that can interfere
with the liftgate installation
3) REAR SILL HEIGHT and DESIGN
- Measure top of floor to bottom of buck plate and verify design regarding to Figure 1

2 Important Notes:
Revision 1.5 - 7 -
Mounting Notes:
Read and clearly understand manual BEFORE beginning ANY work
Important!!!
The basic rule for installing an ILU PALFINGER Liftgate is to MOUNT THE FRAME AS HIGH AS
POSSIBLE
to achieve MAXIMUM GROUND CLEARANCE and MINIMIZE THE “F” DIMENSION.
•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

3 Chassis Dimension SheetsChassis Dimension Sheets
Revision 1.5 - 8 -
Chassis Dimension Sheets 3
D
Fill out and send to Interlift if specific
install drawing is needed
A= Bedheight, top of floor to even ground........
B= Top of floor to bottom of trailer cross member..........
C= Rear sill height, top of floor to bottom of buck plate.........
D= Crossmember height .........
E= Tire to end of body ..........
F= Bogie to end of body ..........
G= Protruding eye brows? yes, dim..... / no
H= Inside vertical width of suspension angles......
Liftgate Type:...............
Type of Body: Van...... Flatbed...... Refer.......
Make.................GVWR...............
Chassis Dimension Sheet
Phone.................... Fax.................... E-mail..........................................
Type of rear door: Roll-up ..... Swing ..... Flip-up...
Trailer
Trailer
H
Verify
flush
treshold
or other
set up
A
E
F
DB C
G
Figure 1 Trailer dimension sheet
me
A= Bedheight...........
B= Top of floor to bottom of frame.........
C= Rear sill height...........
D= Spring hanger to end of body...........
E= Tire to end of body..........
F= Gas tank to end of body (if applicable)..........
G= Bottom of frame to bottom of gas tank........
F
D
E
G
B
A
C
Company:.............................
Liftgate Type:...............
VIN#.............................Make.................GVWR...............
Chassis Dimension Sheet
Fill out and send to Interlift
Phone.................... Fax.................... E-mail..........................................
Truck
Figure 2 Truck dimension sheet

4 Installation Dimensions
Revision 1.5 - 9 -
Installation Dimensions 4
- Installation Dimension sheets are supplied with each individual ILU, as there are too many different
setup combinations for a generic installation drawing. When ordered a liftgate, PALFINGER Liftgates
supplies a drawing based upon the Chassis dimension sheet (Figure 1 and Figure 2) supplied by your
company.
IMPORTANT:
Before starting the installation, make sure that you have your own reference sheet that was supplied to
PALFINGER Liftgates together with the installation lay-out drawing. Compare it with the truck you are about
to start the installation on. If the units are different than the supplied lay-out, contact your supervisor and
PALFINGER Liftgates to go over the differences.
Do not start installation if your truck/trailer does not match up with PALFINGER Liftgates supplied
drawing!
Figure 3 Installation Drawing - provided by PALFINGER Liftgates engineering department

4 Installation Dimensions
Revision 1.5 - 10 -
4.1 General Bed Height Ranges for ILU liftgates.
Minimum bed height is when truck/trailer is loaded to MAX GVW (all dimensions in inches)
ILU 40-50 800mm arm 36”- 56”

4 Installation Dimensions
Revision 1.5 - 11 -
4.2 Chassis and Body Preparation
4.2.1 Mount frame clearance
- Determine the correct mounting clearance according to your specific lift and chassis.
- With long overhangs it is even more important to maintain Max ground clearance.
oGROUND CLEARANCE = BOTTOM OF LIFTGATE FRAME TO GROUND
- Determine if you need to move chassis U-bolts or if you have any other interferences, then
proceed with installing the liftgate slide rails to the frame
IMPORTANT (Truck Installation):
- Before start of installation make sure body long rails are connected to truck frame
welded with flat bars and secured against forward movement of the body
oIf body and frame are not connected lift gate might push body forward
Bed height =top of bed to floor when air bags are
inflated and on flat ground (dim "Y")
Mount frame clearance = dimension from back
of truck to spring / tire or air ride suspension components
that would interfere with liftgate installation (dim "X")
Y
X
Figure 4 Mounting clearance
Flat bars to
connect body and
frame securely

4 Installation Dimensions
Revision 1.5 - 12 -
Eyebrow
cut out to
clear
platform
4.2.2 Rear sill preparation
To assure that the gate is reaching the body floor, you need to cut out the rear sill of your truck/trailer.
•If sill is less than 4“ high No sill cut out needed
•If no cut out height is determined in drawing, cut out for best fit. Keep at least a minimum of 4” of sill.
•Reinforce every cut out of the sill to regain sill strength, required by truck/trailer OEM.
46"
12"
12"
70"
Reinforce cut outs
Figure 5 Sill cut-out dimensions - rear view
Figure 6 Sill cut-out – sideview
To avoid interference with the
body, you need to cut out the
back sill.
Height of the cut out is determined in the gate specific drawing

4 Installation Dimensions
Revision 1.5 - 13 -
•On trailers, you have to check the eyebrow clearance, and in case of interference cut eyebrow down
until platform clears.
•The eyebrow cut out can be done when gate and platform are installed and you raise up gate for the
first time. That gives the opportunity to keep as much of the eyebrow as possible to keep rear frame
strength.
IMPORTANT!!!
•A proper preparation of the truck/trailer sets the basics for a safe, clear and fast installation process
and assures a proper function of the lift gate without damage to truck/trailer or lift gate.

5 Gate Installation
Revision 1.5 - 14 -
Gate Installation 5
Never work under mount frame or platform without safety supports
5.1 Slide rail bracket installation
Figure 7 Slide rail installation
1) Make sure the specific install drawing sent with the liftgate matches the truck and gate you are
about to install.
2) Install the slider rail frame according to drawing sent with the gate. Weld brackets with 2 x 2” of ¼”
welds on each side for adjustment purposes
3) When gate is completely installed and tested for proper function weld a 100% around the
brackets to assure a save and secure connection of gate- and truck frame.
ADD STEEL BACKER PLATE
IF MOUNT BRACKET CAN NOT
BE WELDED 100%.

5 Gate Installation
Revision 1.5 - 15 -
5.2 Liftgate attachment
Figure 8 Liftgate installation to previous installed rails
1) Slide liftgate main frame assembly into previous installed slide rails.
2) Connect pin in front of push-pull cylinder to bracket towards truck cabin.
Figure 9 platform attachment
3) Connect platform to frame by using supplied pins and lock bolts
4) Connect lift arm to inside clevis holes. Tighten lock nuts at pin tab to avoid pin getting loose
5) Connect tilt cylinder to outside holes at clevis. Tighten lock nuts at pin tab to avoid pin getting loose
a. To extend or retract tilt cylinders you have to connect the power supply of the gate (see
chapter 5.4 and chapter 5.3)
b. Hold B-15 sensor in a level position, the cable retainer pointing towards the front of the truck

5 Gate Installation
Revision 1.5 - 16 -
5.3 Control power wiring setup
To maintain the best possible power supply, install the auxiliary batteries as close as possible to the gate.
- Truck installations might not have an auxiliary battery kit (PALFINGER Liftgates always recommends
a kit). In this
case you have to run the control power straight off the truck battery.
- Trailer installations always have a trailer battery kit (at least 2 batteries recommended)
Connect your control power to the positive (#2 & #4) and the negative (#1 & gr/ye) post of the batteries.
Control Power 4-Wire Cable
Truck Application-Always wire to truck battery
Trailer Application-wire to trailer battery
+-
20 Amp
In-Line
Fuse
+-
Wires marked
#2;#4 (Black)
go to hot,
#1 and green/yellow
go to ground
PC-board
227
15 Amp fuses
J1 Plug
#2 #4
++
EE -
-
gr/ye
#1
J2 Plug
Figure 10 Board control power wiring connection
Ground Cable
Ground
at trailer
frame
(Third Battery Shown
for heavy applications Only)
+-
Liftgate Mount Frame
Main Truck
Batteries
2 Ga. Liftgate Power Cable
Ground
+-
+-
To Ignition
Switch
Ground
Aux. Batteries
Battery
Isolator
+-
(if applicable)
Circuit
Breaker
+-
Circuit
Breaker
Tractor -
Trailer
Plug
Figure 11 Main Power supply setup

5 Gate Installation
Revision 1.5 - 17 -
5.4 Platform installation
To install the platform (if not preinstalled by manufacturer) follow these steps:
1) Unfold platform and clamp on to forklift or overhead crane.
2) Slide out gate to the point that you are able to attach platform clevis to lift arm and tilt cylinders.
3) Bring platform close to gate and attach lift arm to platform using provided pins
4) To attach tilt cylinders hold B-15 platform sensor so that you are able to extend tilt cylinders
when turning the tilt switch until you match pinholes on platform and tilt cylinder head
5) If all 4 pins (2 each side) are in place and secured with lock bolts install B-15 sensor to platform
and connect foot control and warning light cables.
6) Push all excessive cable inside platform to protect connections from environmental influences.
T I R E
Cable Cover/Clamp
B-15 Sensor
Liftarm
Platform Profile
Wire Ties
Warning Light/Foot Control
(option) Harness
Loop per drawing
to allow for proper
movement
Figure 12 Platform installation and wiring
5.4.1.1 Swing-door platform modifications
On swing door applications there might be cutouts necessary to clear the lower cam locks
•If cut outs have not been made, damage to platform tip is possible.
•To avoid unnecessary gaps between trailer and platform, keep cut out as small as possible
#3 Install Lift Cylinder pin
#4 Hold B-15 in angle to
extend tilt cylinders till
lined up with platform
#5 plastic cover to
push excessive
cable inside platform
Tilt cylinder
Lift cylinder

5 Gate Installation
Revision 1.5 - 18 -
5.5 Lift arm Up-stop installation and rail stops setup
With gate power set up and fully functional, place gate and platform in final operational position for
installation of up and slide out stops. Start with up stops and verify flush fit, then continue with slide stops.
Figure 13 Installation of up-stops
Assure that platform main section is not set under pressure against truck/trailer body when install up stops
With Up-stops and slide stops in place, run gate through several cycles and check perfect match of gate
and body floor. Make sure slide stops are tight and alignment of platform and body is ok.
- Make sure platform is aligned
and flush with floor.
- Up Stops
MUST
be installed to
avoid damage to platform or sill
- Install stops when 3/16” Angle
is still between platform and
body
- make sure Up-stops are sitting
tight against lift arm when
platform in upper position
3/16“
Use 3/16“ Angle
to create gap
Gate main frame mount plate
Mount plate slide stop
When platform is in
correct position (see
Figure 13) and up stops
are in place, set slide
stops tight against
Mount plates and fasten
bolts tight with counter
nut.
Figure 14 Mount plate slide stops
Slide stop
adjustment screw
with counter nut

5 Gate Installation
Revision 1.5 - 19 -
5.6 Control box installation
Install the control box on the passenger side mounted arm. Run the cable along the slide rail and tie it down
so it cannot interfere with the mount plates when gate is sliding in or out.
Figure 15 Control box placement

6 Gate adjusting and detailing
Revision 1.5 - 20 -
Gate adjusting and detailing 6
6.1 Setting B-13 lift arm sensor
10"-12"
Sensor horizontal
in this position
B-13
Lift Arm
Lift Cylinder
B-13 Sensor
Lock Tab Tilt Cylinder
Figure 16 B-13 lift arm adjustment
•To set the sensor correctly, lift unfolded platform up about 10” to 12” above ground.
•Adjust the B-13 sensor in an way that it is level with the ground like shown in Figure 16.
•Raise gate all the way up after adjusting and lower to the ground. Platform tip will tilt towards ground if
operator stays on the lower switch for about “3” seconds after nylon rollers touching ground
•Cycle platform several times to check operation after tightening
•Fold down Lock Tab tightly onto Lift Arm (see Figure 16)
•At NO time the platform tip should tilt towards ground while lowering.
•Platform should only tilt after Nylon rollers contact ground and operator is on the down switch.
•After sensor is properly set, tighten lock bolt to 43 in.lbs/3.5 ft.lbs
•Never over torque B-13 lock bolt. Sensor will break and malfunction.
•Verify colored side of sensor is out (facing away from arm)
•Under torqueing B-13 lock bolt may allow sensor to shift during normal gate operation.