Palfinger LIFTGATES ILM plus Series Operating instructions

Rev-07272022 P1
ILM plus –Series
Troubleshooting: ILM Medium Duty Railgate Lift
Table of content: Page
1) Gate overview ………………………………………………......2
2) Pump and Motor Setup overview …….…….………………….3
3) Controller Identification Overview .…………………………….4
4) Chain routing ( Standard ILM+ ) .…………….……………….5
5) Chain routing ( Above floor ILM+ ) …………………………….6
6) Gate does not opening up.…………….….…….……………...7
7) Gate is not lowering down .…………….……….……………..8
8) Gate is not raising up……………………...….................…….9
9) Gate is not closing ……………………….….……………..….10
10) Electrical Diagram Manual Closing .…………….................11
11) Hydraulic Schematic Manual Closing …………………….....12
12) Hydraulic Schematic MC Lift Function ………………….…. 13
13) Hydraulic Schematic MC Lower Function ………............... 14
14) Electrical Diagram Power Closing…..………………….........15
15) Hydraulic Schematic Power Close …...……….…………....16
16) Hydraulic Schematic PC Lift Function ………...…………... 17
17) Hydraulic Schematic PC Open Function ….…………….… 18
18) Hydraulic Schematic PC Lower Function ……………….… 19
19) Hydraulic Schematic PC Close Function ……………….… .20
20) Platform not lowing down Test ………………….………….. 21
21) Check ground on solenoid valves………………………….. 22
22) Testing solenoid valves and cables ……………………….. 23
23) Pump pressure adjustment ………………………………….24
24) Gate chattering or sticking in rails Inspection Steps.25,26,27,28.
25) Palfinger Technical Support & Parts Contact list ………… 29
*****MAKE SURE YOUR BATTERIES ARE FULLY CHARGED AND IN GOOD CONDITION*****
Tools needed:
1.) Voltmeter
2.) Test light
3.) 8” jumper cable (16ga. or smaller)
4.) Philips Screw driver
5.) 13mm (1/2”) wrench
Always use CAUTION and allow SAFE distance from moving parts
Practice SAFETY, using common sense and good judgment

2
Gate overview
ILM plus
Series
Rail
Platform
Storage
Latch
Lift
Cylinder
(Inside)
Runners
Safety
Storage
Latch
Side
Chain
Power
Open/Close
Cylinder
(if applicable)
Operating
Controls
Rail
Platform
Storage
Latch
Load
Center of
Gracity
Hydraulic
Power Unit
(Inside)
Serial # tag
13
510
1
6
6
12
15.1
15.4
15.2
15.3
15.6
11
7
15.5
2.3
2.1
4
3
14
8
9
9
15.3
15.2
15.5
15.4
15.1
15.6
15
2.1
2.2
2.3 2
2.3
2.3
16.3
16.2
16.5
16.4
16.1
16.6
16
17
15.2
15.3
7
18
Open/Close
Restrictor location

3
Pump and Motor Setup Overview
Hydraulic
Hose
S1 Lift/Lower
Valve
Motor
Solenoid Reservoir
Motor S2 Open/Close
Valve
Lift Cylinder Pressure
Adjustment Filler Vent Cap
ILM plus
Series
Oil Filler
Cap
Oil
Reservoir
1"
Hydraulic Power Unit
Hydraulic Fluid Installed From Factory
Property HYDREX MV ARCTIC 15
Start Up Temperature <50°C / -58°F
Operating Temperature -45°C to +23°C / -49°F to 73°F
Pour Point -57°C / -71°F
Flash Point 128°C / 262°F
Density 15°C (59° F). kg/L
0.834
Viscosity:
cSt @ 40°C/SUV @ 100°F
cSt @ 100°C/SUV @ 210°F
cP @ -50°C (-58°F)
13.0 / 69.7
4.95 / 42.5
1,310
Alternative Fluids
Temperature Range Fluid Brand
30°TO 150°F
EXXON UNIVIS J26
MOBIL DTE 13M
CHEVRON AW MV32
ROSEMEAD MV 150 (32)
-50°TO 150°
MOBILE DTE 11
SHELL AERO FLUID 4/41
SHELL TELLUS 15
Extreme Cold Temperature MIL H5606 (Military Spec.)
Swivel
Joint on
Hose
Lift
Cylinder
Hydraulic
Hose
Swivel
Joint on
Hose
Lift
Cylinder
Hydraulic
Hose

4
Controller Identification & Operation Overview
Power Open and Close will have three button controller
ILM plus
Series
Lower Solenoid - Black
Close - White
Ground - Lower Solenoid- Black
Closing Solenoid
GND
5/16-18 UNC-2B
Ground
Load
Power
Cab Cut-Off Switch
70-1012-002
2025982 Cab Switch Harness
Ground - Yellow/Green
Load - Blue
Power - Brown
15AFuse
Power - Black
70-0709-901
Main Liftgate
3-Button Control
Lower - Black
Starter - Green
Power - Red
70-0709-906
Remote Harness for
Optional 2-Button Control
or Toggle Switch
Raise - #5 - Brown
Lower - #6 - Yellow/Green
Power - #4- Blue
Raise - Green #5
Lower - Black #6
Power - White #4
70-0709-903
Optional Inside
Coil Cord Remote
2-Button Control
Seal with
Heat Shrink
Seal with
Heat Shrink
Raise - Green
Lower - Black
Power - Red
Lower Solenoid - Black
Ground - Lower Solenoid- Black
Lower Solenoid
P-2004565
Optional Inside
Hard MountToggle Switch
15939 PiumaAve. Cerritos, CA 90703
ILM Wiring Schematic - Power Closing
Important Notes:
-All connectors are to be insulated and weather sealed.
-In-LineATC Fuse 15Amp at solenoid.
Replace with
same amperage fuse when necessary.
NOTICE: DO NOT attempt to jump in-line fuses
with other objects other than the specified fuse(s).
DO NOT increase the amperage rating of fuse.
Serious harmto the liftgate will result when
standard practices are not followed.
12V Power Supply
150amp
Circuit Breaker
25 Ft. x 4 ga.
Battery Cable
Manual Open and Close will have two button controller
Lower Solenoid - Black
Close - White
Ground- Lower Solenoid - Black
Closing Solenoid
GND
5/16-18 UNC-2B
Ground
Load
Power
Cab Cut-Off Switch
70-1012-002
2025982 Cab Switch Harness
Ground - Yellow/Green
Load - Blue
Power - Brown
15AFuse
Power - Black
70-0709-901
Main Liftgate
3-Button Control
Lower - Black
Starter - Green
Power - Red
70-0709-906
Remote Harness for
Optional 2-Button Control
or Toggle Switch
Raise - #5 - Brown
Lower - #6 - Yellow/Green
Power - #4 - Blue
Raise - Green #5
Lower - Black #6
Power - White #4
70-0709-903
Optional Inside
Coil Cord Remote
2-Button Control
Seal with
Heat Shrink
Seal with
Heat Shrink
Raise - Green
Lower - Black
Power - Red
Lower Solenoid - Black
Ground- Lower Solenoid - Black
Lower Solenoid
P-2004565
Optional Inside
Hard Mount Toggle Switch
15939 PiumaAve. Cerritos, CA 90703
ILM Wiring Schematic - Power Closing
Important Notes:
-All connectors are to be insulated and weather sealed.
-In-LineATC Fuse 15Amp at solenoid.
Replace with
same amperage fuse when necessary.
NOTICE: DO NOT attempt to jump in-line fuses
with other objects other than the specified fuse(s).
DO NOT increase the amperage rating of fuse.
Serious harmto the liftgate will result when
standard practices are not followed.
12VPower Supply
150 amp
Circuit Breaker
25 Ft. x 4 ga.
Battery Cable
Diode
Diode Inside Remote Schematic
Motor Solenoid
S1 Lift/Lower Valve
Green Wire
Diode
Red Jumper Wire
Red Wire 12 Volt Power
Black Wire
Inside Remote Schematic
S1 Lift/Lower Valve
S2 Open/Close Valve
Red Wire 12 Volt Power
Motor Solenoid
Black Wire
Green Wire
White Wire Diode

5
ILM plus
Series
Chain Routing –Standard ILM+

6
ILM plus
Series
Chain Routing –Above Floor ILM+

7
1) GATE DOES NOT OPEN UP
b) Platform is not opening up
→Check if both valves on cylinder are energized.
→If not, check power supply to switches and signal line to valves while activating open function
→Valves are energized –check grounding of valves
→Valves are energized, but Platform still does not open
→Check coil for damage and magnetic function
→Check Gas Shocks on side of platform for damage or seized
→Check open /close cylinder for damage or leaks
a) Initial Checks
→Check Cab Switch is "ON“ ( Optional )
→Check that Circuit Breaker at battery box has not been tripped
→Check that 15 amp fuse at Motor Solenoid is ok
→Check for shorts, ground faults or open circuits, e.g., power lines connected to the ground
or a broken cable or connection
→Check batteries. Batteries should be fully charged and in good condition
→Check voltage - minimum 10 volts at motor when closing or up function is engaged for 10 sec with gate
in stored position.
ILM plus
Series

8
2) GATE IS NOT LOWERING DOWN
a) Initial Checks
→Check Cab Switch is "ON“ ( Optional )
→Check that Circuit Breaker at battery box has not been tripped
→Check that 15 amp fuse at Motor Solenoid is ok
→Check for shorts, ground faults or open circuits, e.g., power lines connected to the ground
or a broken cable or connection
→Check batteries. Batteries should be fully charged and in good conditions
→Check voltage - minimum 10 volts at motor while activating the UP function with gate in upper position
b) Platform is not lowering down
→Raise gate up just under pump and motor mounting plate remove hydraulic line at pump and remove
vent cap on reservoir and place line inside hole for vent and press down button on controller (first making
sure all obstacle's are clear and operator is safely clear) If gate lowers with this test then problem is in
pump assembly, remove and replace pump and motor assembly.( for this test see illustration on page 13 )
→Check if Lift/Lower valve on cylinder is energized.
→If not, check power supply to up/down switch and signal line to Lift/Lower valve while activating
lowering function (check for voltage while activating function)
→Valve is energized –check grounding of valve and make sure, ( see pictures on page 14 ) valve is
shifted over (hear click)
→Valve is energized, but Platform still does not lower down
→Check if open/close valve is energized –it should NOT be energized.
→Check if flow control valve is contaminated and/or cylinder is damaged
ILM plus
Series

9
3) GATE IS NOT RAISING UP
b) Motor does not run
→Check power supply to up/down switch and for voltage at signal line to motor solenoid
while activating up function
→Check motor solenoid. If it is getting power (small connector at solenoid has voltage) but you do not
hear a click, you should change the motor solenoid.
→You hear it click - check if the motor gets power. If yes, check the motor of correct function.
c) Motor runs but platform does not raise
→Check lift cylinder for damage or chain for broken chain links. ( See drawings page 15 & 16 )
a) Initial Checks
→Check Cab Switch is "ON“( Optional )
→Check that Circuit Breaker at battery box has not been tripped
→Check that 15 amp fuse at Motor Solenoid is ok
→Check for shorts, ground faults or open circuits, e.g., power lines connected to the ground
or a broken cable or connection
→Check batteries. Batteries should be fully charged and in good condition
→Check voltage - minimum 10 volts at motor after 10 sec holding the switch for closing function.
(Deadhead the gate in actual position)
ILM plus
Series

10
4) GATE IS NOT CLOSING
a) Initial Checks
→Check Cab Switch is "ON“( Optional )
→Check that Circuit Breaker at battery box not been tripped
→Check that 15 amp fuse at Motor Solenoid is ok
→Check for shorts, ground faults or open circuits, e.g., power lines connected to the ground
or a broken cable or connection
→Check batteries. Batteries should be fully charged and in good condition
→Check voltage - minimum 10 volts at motor at while holding the up function for 10 seconds (Deadhead)
b) Motor is not running
→Check power supply to open/close and up/down switch and for voltage at motor solenoid and
open/close valve while activating up function
→Check motor solenoid. If it is getting power but you do not hear click, you should change the motor
solenoid.
→You hear it click, check if the motor gets power. If yes, check the motor of correct function.
d) Motor is running, but platform does not close
→Check for power at open/close valve
→Check cylinder for leaking, loose fittings or contaminated restrictor
→Check the hydraulic oil level, low level oil in the reservoir –fill up and activate closing function
ILM plus
Series

11
ILM plus
Series
25 Ft. x 4 ga. Battery Cable
150amp Circuit Breaker
12VPower Supply
Important Note:
-All connectors are to be insulated and weather sealed.
-In-LineATC Fuse 15Amp at solenoid.
Replace with
same amperage fuse when necessary.
NOTICE: DONOT attempt to jump in-line fuses
with other objects other than the specified fuse(s).
DO NOTincrease the amperage ratingof fuse.
Serious harm to the liftgate will result when
standard practices are not followed.
ILMWiring Schematic - Manual Closing
15939 Piuma Ave. Cerritos, CA 90703
*Asecond valve applies to a power close units
P-2004565
Optional Inside
Hard Mount Toggle Switch
Lower Solenoid
Ground- Lower Solenoid- Black
Lower Solenoid- Black
Power - Red
Lower - Black
Raise - Green
Seal with Heat Shrink
Seal with Heat Shrink
70-0709-903
Optional Inside
Coil Cord Remote
2-Button Control
Power - White #4 Lower - Black #6 Raise - Green #5
Power - #4 - Blue
Lower - #6 - Yellow/Green
Raise - #5 - Brown
70-0709-906
Remote Harness for
Optional 2-Button Control
or Toggle Switch
Power - Red
Starter - Green
Lower - Black
70-0709-902
Main Liftgate
2-Button Control
Power - Black
15AFuse
Power - Brown
Load - Blue
Ground - Yellow/Green
2025982 Cab Switch Harness
Optional Cab Cut-Off Switch
70-1012-002
Power
Load
Ground
Ground - Yellow/Green
Cab Shut Off Switch
- Unplug Red (from Hand Held Control)
and Black (from fuse) wires.
- Connect Brown & Black wires.
- Connect Blue & Red wires.
GND
Wiring Diagram (Manual Closing)
S1
Lift/Lower Release Valve
Ground-Black Lift/Lower Valve
Black Lift/Lower Valve
Green-Motor Solenoid
Lift
Lift
Lift

12
ILM plus
Series
15939 Piuma Ave. Cerritos, CA 90703
ILMWiring Schematic - Manual Closing
Lift Cylinder Cylinder Valve Body
Pump Unit
Relief Valve
2900 psi
Filter
Pump
FlowControl
Press-Comp 1.0 gpm
Port
Port
Cap Port
Locking Valve Main Cylinder
Shuttle Valve
Reservoir Tank
Hydraulic Schematic (Manual Closing)
S1
Lift/Lower Valve
Motor
Motor

13
ILM plus
Series
15939 Piuma Ave. Cerritos, CA 90703
ILMWiring Schematic - Manual Closing
Lift Cylinder Cylinder Valve Body
Pump Unit
Relief Valve
2900 psi
Filter
Pump
FlowControl
Press-Comp 1.0 gpm
Port
Port
Cap Port
Locking Valve Main Cylinder
Shuttle Valve
Reservoir Tank
Hydraulic Schematic (Manual Closing)
M
Lift Function
Green = 12 Volt Power Active
Red = High Pressure
Blue = Low Pressure
Lift Function
Motor & S1 Valve
S1
Lift/Lower Valve

14
ILM plus
Series
15939 Piuma Ave. Cerritos, CA 90703
ILMWiring Schematic - Manual Closing
Lift Cylinder Cylinder Valve Body
Pump Unit
Relief Valve
2900 psi
Filter
Pump
FlowControl
Press-Comp 1.0 gpm
Port
Port
Cap Port
Locking Valve Main Cylinder
Shuttle Valve
Reservoir Tank
Hydraulic Schematic (Manual Closing)
Lower Function
Green = 12 Volt Power Active
Red = High Pressure
Blue = Low Pressure
Lowering Function
S1 Valve
S1
Motor
Lift/Lower Valve

15
ILM plus
Series
Lower Solenoid - Black
Close - White
Ground- Lower Solenoid- Black
Closing Solenoid
GND
5/16-18 UNC-2B
Ground
Load
Power
Cab Cut-Off Switch
70-1012-002
2025982 Cab Switch Harness
Ground - Yellow/Green
Load - Blue
Power - Brown
15AFuse
Power - Black
70-0709-901
Main Liftgate
3-Button Control
Lower - Black
Starter - Green
Power - Red
70-0709-906
Remote Harness for
Optional 2-Button Control
or Toggle Switch
Raise - #5 - Brown
Lower - #6 - Yellow/Green
Power - #4 - Blue
Raise - Green #5 Lower - Black #6 Power - White #4
70-0709-903
Optional Inside
Coil Cord Remote
2-Button Control
Seal with Heat Shrink
Seal with Heat Shrink
Raise - Green
Lower - Black
Power - Red
Lower Solenoid - Black
Ground- Lower Solenoid- Black
Lower Solenoid
P-2004565
Optional Inside
Hard Mount Toggle Switch
15939 Piuma Ave. Cerritos, CA 90703
ILMWiring Schematic - Power Closing
Important Notes:
-All connectors are to be insulated and weather sealed.
-In-LineATCFuse 15Amp at solenoid.
Replace with
same amperage fuse when necessary.
NOTICE: DONOT attempt to jump in-line fuses
with other objects other than the specified fuse(s).
DO NOT increase the amperage rating of fuse.
Serious harmto the liftgate will result when
standard practices are not followed.
12VPower Supply
150amp Circuit Breaker
25 Ft. x 4 ga. Battery Cable
Wiring Diagram (Power Closing )
25 Ft. x 4 ga.
Battery Cable
150amp
Circuit Breaker
12VPower Supply
Important Note:
-All connectors are to be insulated and weather sealed.
-In-LineATC Fuse 15Amp at solenoid.
Replace with
same amperage fuse when necessary.
NOTICE: DO NOT attempt to jump in-line fuses
with other objects other than the specified fuse(s).
DO NOTincrease the amperage ratingof fuse.
Serious harm to the liftgate will result when
standard practices are not followed.
ILMWiring Schematic - Manual Closing
15939 Piuma Ave. Cerritos, CA 90703
*Asecond valve applies to a power close units
P-2004565
Optional Inside
Hard Mount Toggle Switch
Lower Solenoid
Ground- Lower Solenoid- Black
Lower Solenoid- Black
Power - Red
Lower - Black
Raise - Green
Seal with
Heat Shrink
Seal with
Heat Shrink
70-0709-903
Optional Inside
Coil Cord Remote
2-Button Control
Power - White #4
Lower - Black #6
Raise - Green #5
Power - #4 - Blue
Lower - #6 - Yellow/Green
Raise - #5 - Brown
70-0709-906
Remote Harness for
Optional 2-Button Control
or Toggle Switch
Power - Red
Starter - Green
Lower - Black
70-0709-902
Main Liftgate
2-Button Control
Power - Black
15AFuse
Power - Brown
Load - Blue
Ground - Yellow/Green
2025982 Cab Switch Harness
Optional Cab Cut-Off Switch
70-1012-002
Power
Load
Ground
Ground - Yellow/Green
Cab Shut Off Switch
- Unplug Red (from Hand Held Control)
and Black (from fuse) wires.
- Connect Brown & Black wires.
- Connect Blue & Red wires.
GND
S1
Lift/Lower Valve Open/Close Valve
S2
Ground-Open/Close Valve-Black
Lift
Lift
Ground-Lift/Lower Valve-Black
Lift
Open/Close Valve - Black
Lift/Lower Valve - Black
Motor Solenoid

16
ILM plus
Series
15939 Piuma Ave. Cerritos, CA 90703
ILMWiringSchematic - Power Closing
Lift Cylinder Cylinder Valve Body
Closing Cylinder
Pump Unit
Relief Valve
2900 psi
Filter
Pump
FlowControl
Press-Comp 1.0 gpm
Port
Port
Port
FlowControl
Fixed #035
Locking Valve Main Cylinder
Locking Valve Closing Cylinder
Shuttle Valve
Reservoir Tank
Hydraulic Schematic (Power Closing)
S1 S2
Open/Close Valve
Lift/Lower Valve
Motor

17
ILM plus
Series
15939 Piuma Ave. Cerritos, CA 90703
ILMWiring Schematic- Power Closing
Lift Cylinder Cylinder Valve Body
Closing Cylinder
Pump Unit
Relief Valve
2900 psi
Filter
Pump
FlowControl
Press-Comp 1.0 gpm
Port
Port
Port
FlowControl
Fixed #035
Locking Valve Main Cylinder
Locking Valve Closing Cylinder
Shuttle Valve
Reservoir Tank
Hydraulic Schematic (Power Closing)
Green = 12 Volt Selected
Red = High Pressure
Blue = Low Pressure
Lower Function
Lowering Function
S1 Valve
S1 S2
Motor
Lift/Lower Valve
Open/Close Valve

18
ILM plus
Series
15939 Piuma Ave. Cerritos, CA 90703
ILMWiring Schematic- Power Closing
Lift Cylinder Cylinder Valve Body
Closing Cylinder
Pump Unit
Relief Valve
2900 psi
Filter
Pump
FlowControl
Press-Comp 1.0 gpm
Port
Port
Port
FlowControl
Fixed #035
Locking Valve Main Cylinder
Locking Valve Closing Cylinder
Shuttle Valve
Reservoir Tank
Hydraulic Schematic (Power Closing)
Green = 12 Volt Selected
Red = High Pressure
Blue = Low Pressure
Open Function
Open Function
S2 Valve
S1 S2
Motor
Lift/Lower Valve
Open/Close Valve

19
ILM plus
Series
15939 Piuma Ave. Cerritos, CA 90703
ILMWiring Schematic- Power Closing
Lift Cylinder Cylinder Valve Body
Closing Cylinder
Pump Unit
Relief Valve
2900 psi
Filter
Pump
FlowControl
Press-Comp 1.0 gpm
Port
Port
Port
FlowControl
Fixed #035
Locking Valve Main Cylinder
Locking Valve Closing Cylinder
Shuttle Valve
Reservoir Tank
Hydraulic Schematic (Power Closing)
Green = 12 Volt Selected
Red = High Pressure
Blue = Low Pressure
Lift Function
M
Lift Function
Motor & S1 Valve
S2
S1
Lift/Lower Valve
Open/Close Valve

20
ILM plus
Series
15939 Piuma Ave. Cerritos, CA 90703
ILMWiring Schematic- Power Closing
Lift Cylinder Cylinder Valve Body
Closing Cylinder
Pump Unit
Relief Valve
2900 psi
Filter
Pump
FlowControl
Press-Comp 1.0 gpm
Port
Port
Port
FlowControl
Fixed #035
Locking Valve Main Cylinder
Locking Valve Closing Cylinder
Shuttle Valve
Reservoir Tank
Hydraulic Schematic (Power Closing)
Green = 12 Volt Selected
Red = High Pressure
Blue = Low Pressure
Close Function
M
Close Function
Motor & S2 Valve
S1 S2
Lift/Lower Valve
Open/Close Valve