ILM+ IM v1.7 1013 - static.palfinger.com

ILM

INSTALLATION MANUAL & CHECK-OFF SHEET

ECN-M0322 Rev. 1.7, Date 10-23-2013 Part #90-0709-200

PALFINGER Liftgates, LLC. 15939 Piuma Ave., Cerritos, CA 90703

Tel (888)-774-5844 Fax (562)-924-8318

PALFINGER Liftgates, LLC. 572 Whitehead Road, Trenton, NJ 08619

Tel (609)-587-4200 Fax (609)-587-4201

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

Company Information:

Company Name:

Advisor Name:

Truck/Trailer Year Make & Model:

Liftgate Information:

Liftgate Serial Number:

Liftgate Model Number:

Date of Purchase:

Date of Installation:

ILM Installation Manual

Table of contents

1 Safety Information .................................................................................................................... 1

2 Important Information ............................................................................................................... 2

3 Tools For Installation ................................................................................................................ 4

4 General View of Liftgate ........................................................................................................... 5

4.1 General Figures ............................................................................................................ 5

5 Installation Dimensions ............................................................................................................ 6

5.1 Important Dimensions ................................................................................................... 6

5.2 Installation Dimensions ................................................................................................. 7

5.3 Strength Requirements ................................................................................................. 8

5.4 Width Requirements ...................................................................................................... 9

6 Body Preparation ...................................................................................................................... 10

6.1 Rear Bumper ................................................................................................................. 10

6.2 Tow Hitch/Auxiliary Equipment ...................................................................................... 11

6.3 Flush the Sill (Sub- Framing) ......................................................................................... 12

6.4 Support Body ................................................................................................................ 14

6.5 Add Alignment Bars (Optional) ...................................................................................... 15

7 Liftgate Preparation .................................................................................................................. 16

8 Gate Installation ........................................................................................................................ 17

8.1 Hoisting the Liftgate ....................................................................................................... 17

8.2 Check Liftgate Dimensions ............................................................................................ 19

8.3 Welding Liftgate ............................................................................................................ 20

8.4 Trimming Excess Column .............................................................................................. 22

8.5 Installation of bracket for Control Unit ............................................................................ 23

9 Electrical Installation ................................................................................................................ 24

9.1 Main Power Connections............................................................................................... 24

9.2 Basic Wiring (Manual Closing) ...................................................................................... 25

9.3 Basic Wiring (Power Down Liftgate) .............................................................................. 26

10 Lubrication ................................................................................................................................ 27

11 Cycle Test and Final Inspection ............................................................................................... 29

11.1 Cycle Test and Bleed the hydraulic system. .................................................................. 29

11.2 Decal Placement and inspection ................................................................................... 31

11.3 Final Inspection Check List ............................................................................................ 34

ILM Installation Manual Chapter 1

Revision 1.7 - 1 -

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.

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 or death.

! 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 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.)


Revision 1.7 - 2 -

2 Important Information

Before Getting Started

“READ FIRST”

The ILM Plus is an 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.

• Read and understand the “Installation Manual” and “Owner’s Manual” in their entirety before starting your 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.

• Persons should never position themselves underneath the liftgate if it is not fully welded.

• 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 kept in your records for future reference.

• Refer to owner’s manual for operation and maintenance information.


Revision 1.7 - 3 -

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 ILM liftgate. It also provides safety information and simple preventive maintenance tips.

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 ILM series liftgate only which is designed for different capacities. There are four options available to determine the model and serial number of the installed liftgate:

1) Refer to the serial number tag on the liftgate (Located on Driver Side Column- See figure below)

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 (562) 924-8318 or on the internet- www.palfinger.com For technical support, contact PALFINGER Liftgates or an authorized PALFINGER service center. www.palfinger.com Replacement manuals are available at no charge by contacting Customer service at 888-774-5844

Location of Nameplate


Revision 1.7 - 4 -

3 Tools For Installation

SAE & 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.

Sm. To Med. Bottle Jack

Forklift or O/H 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. 30” Pry Bar Rivets &Rivet Gun

Table 3-1: Suggested Installation Tools


Revision 1.7 - 5 -

4 General View of Liftgate

4.1 General Figures

Figure 4-1: ILM plus General View

LOAD CENTER OF

Side Chain

Hydraulic

Power Unit

Lift Cylinder

Safety- Storage

Latch

Control Buttons

Power Open/ close

Version

Platform Storage

Latch

Rail

Above Floor Option


Revision 1.7 - 6 -

5 Installation Dimensions

5.1 Important Dimensions

Minimum Bed Height dimensions are ALWAYS MAXIMUM LOADED TRUCK.

Maximum Bed Height dimensions are ALWAYS DRY UNLOADED TRUCK.

Ensure truck body or trailer rear door does not interfere with installation or operation of ILM plus

series liftgate. The ILM plus series cannot be installed with "barn" or "swing" type doors without

extensive modification.

It is not recommended to cut, torch, or remove support materials from rear sill of truck or trailer.

Installers are advised to sub-frame or flush sills as required. Removing gussets, stiffeners, light rings,

or other such support structures may VOID your truck/trailer warranty.

Call tech support before starting the installation if you have any questions or concerns on mounting dimensions or procedures… 888-774-5844


Revision 1.7 - 7 -

Max Bed Height 54"

Standard 51-1/2"

Above Floor 59-1/2"

Ground Clearence 18"

3" Column

10" Max

6" Box

Floor/Bed Height

5.2 Installation Dimensions

To determine liftgate compatibility, follow the steps below:

Steps:

1. Measure Floor Height: Measure the floor height of your truck and determine clearance requirements for

your liftgate platform size.

2. Verify Compatibility: Reference the chart below to ensure your gate is compatible with your vehicles bed

height.

Table 5-1: ILM Plus Dock Loading Bed Height Chart Platform Depth Dock Loading Bed height

Range NO Dock Loading Bed Height

Range

Min. Max. Min. Max.

30" + Folding 35" 54" 30" 54"

30" + 6" 39" 54" 30" 54"

36" + Folding 41" 54" 30" 54"

36" + 6" 45" 54" 30" 54"

42" + Folding 47" 54" 30" 54"

42" + 6" 51" 54" 30" 54"

Figure 5-1: Truck Mounting


Revision 1.7 - 8 -

Z

Z

Y

Y

X

X

5.3 Strength Requirements

Reference the chart below for side wall requirements. Ensure that the body side wall, corner post, and rear sill strength requirements are met for your liftgate.

Truck body or trailer must be capable of supporting minimum forces and

loads shown below.

Table 5-2: Side Wall Requirements Chart ILM 16 ILM 20 ILM 25 ILM 30

X = Side Wall Tension 1000 lbs. 1200 lbs. 1500 lbs. 1800 lbs. Y = Side Wall Compression 1000 lbs. 1200 lbs. 1500 lbs. 1800 lbs. Z = Side Wall Shear 1300 lbs. 1500 lbs. 1800 lbs. 2000 lbs.

Figure 5-2: Liftgate Forces


Revision 1.7 - 9 -

5.4 Width Requirements

Reference the chart below to determine liftgate width dimensions. Ensure that your vehicle meets these

requirements.

The ILM plus series liftgate is offered in three widths for most standard bodies. Standard 94” OD for 96” wide bodies. (most common) Optional 100” OD for 102” wide bodies. Optional 88” OD for 90” wide bodies

Outside Frame Width

Inside Frame Width

7" Sprocket Box

51 1/2"

8"

16 1/2"

1"

Table 5-3: Liftgate Width Requirements Chart

Nominal Truck or Trailer Width

Liftgate Outside Frame

Liftgate Inside Frame

Liftgate Platform Width

90” Wide Body 88” 82” 82” 96” Wide Body 94” 88” 88” 102” Wide Body 100” 94” 94”

Figure 5-3: Diagram of Liftgate Dimensions


Revision 1.7 - 10 -

Bed LevelRear Sill

Rear BumperNeeds to be mounted Flush with Sill.

Rear SillBed Level

Rear Sill

90°

Rear BumperFlush with sill.

6 Body Preparation

In order to install your ILM series liftgate, some body preparation may be required. Truck and trailer

applications with flush corner post and sill and NO protruding gussets or stiffeners are the most straight

forward of all ILM installations. Rear of body should be 90` to ground.

Note: Disconnect battery before welding to avoid damage to the truck or trailer’s electrical system.

6.1 Rear Bumper

Steps:

1. Prep rear sill: Remove any sill or corner post mounted lights, grab handles, or bumpers. Your goal is to

have a flat and flush mounting surface for the liftgate.

It is not recommended to cut, torch, or remove support materials from rear sill of truck or trailer.

Installers are advised to sub-frame or flush sills as required. Removing gussets, stiffeners, light rings,

or other such support structures may VOID your truck body or trailer warranty.

2. Remove Rear Protrusions: Be certain that under ride bumpers, trailer hitches, or other auxiliary

equipment do not extend rearward of rear sill. Use the following illustrations as a guide.

Figure 6-1: Vehicle with Protruding Rear Bumper (Left) and Vehicle with Flush Mounted Rear Bumper (Right)

NOT Acceptable Acceptable


Revision 1.7 - 11 -

6.2 Tow Hitch/Auxiliary Equipment

Steps:

1. Relocate Hitch (If applicable): Trailer Hitches are common truck or trailer equipment and are compatible

with the ILM plus series, however they must not stick out further than the rear sill (See Figure 6-2

below). Relocate or remove tow hitch or other auxiliary equipment (If necessary).

If the tow hitch or other auxiliary equipment must be removed or adjusted, ensure that work is done by

a qualified professional. Removing or relocating tow hitches or other equipment may void the

warranty.

Bed LevelRear Sill

Hitch or other Equipment must NOTextend rearward of rear sill.

Figure 6-2: Example of tucked Hitch/Auxiliary equipment


Revision 1.7 - 12 -

Corner Post

Sub-Frame

Liftgate

Corner Post

Sub-Frame Flat Bar

Liftgate

6.3 Flush the Sill (Sub- Framing)

Steps:

1. Flush the sill: Some trucks or trailers may have configurations with irregular shaped sills. Liftgate

mounting surface may NOT be flush with corner post. Some sills may be inset or have door gutters.

All these situations are remedied with a process called sub-framing and/or flushing the sill.

Sub-framing is done one of two ways; Sub-frame can be built up using correct size 3/16” or greater wall tubing before liftgate is mounted. Or, the liftgate can be mounted into position and sub-frame can be built as liftgate is installed with 3/16” or greater flat bar. In either case, liftgate installation weld procedure does not change. These examples are show below. Flushing floor or filling gap between Sill and liftgate can be done up to 6” without cross supports. Use ¼” or greater flat bar or diamond plate to span gap. Original width of the truck frame should be matched as close as possible.

Bed Level Corner Stiffener

Light Box

Corner Post

Liftgate Mounting Surface

Liftgate Platform Surface

Gap between Sill and Liftgate

Figure 6-3: Diagram of Rear Sill (Above)

Tubing sub-frame Flat Bar sub-frame

Figure 6-4: Top View of Sub-

Frame examples


Revision 1.7 - 13 -

2. Flat Bar Posts (if necessary): Corner stiffeners are common and should NOT be removed. It is

recommended to “flat bar” with same thickness as stiffeners, typically ¼” to 3/8” thick x 3” wide. Liftgate

Installation weld procedure is the same.

Corner Stiffener

Corner Stiffener

Flat Bar

Flat Bar

Flat Bar

Figure 6-5: Flat Bar placed to fill the gap between mounting surface and liftgate


Revision 1.7 - 14 -

6.4 Support Body

Side supports can be used to strengthen body.

Steps:

1. Add body supports (If necessary): If extra support is required, add support bars. Refer to Strength

Requirements section 5.3.

Flatbed installation may use similar arrangement with 3/16” x 4” x 4”min. rectangular tubing for corner

post and 3” channels for support bar.

72"

Approx. 60"

Support Bar1/4" x 3" Min. Flat Bar

1/4" x 100% weld each end

Sub-plate for alum side rails1/4" x 4" Min. bolted either side

of body cross member.

Figure 6-6: Support Bar Diagram


Revision 1.7 - 15 -

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 EdgeBed Extension Must Be Flush With

Channel or Equiv.

Channel extends 5" beyond end of bed extension for platform installation.

5"

6.5 Add Alignment Bars (Optional)

The liftgate should be installed level to the rear sill. One method of doing this is to weld two alignment bars to

the rear sill. This acts as a “stop” as the liftgate is hoisted up. This step should be done before the liftgate is

raised to the vehicle. Other methods may also be used.

Steps:

1. Weld Alignment Bars: Weld two (2) supports to the sill of the truck (See Figure 6-7 below). This will

help ensure even alignment between liftgate crossbeam and body sill. Use 3” angle or channel

approximately 10” long.

Figure 6-7: Alignment Bar Diagram


Revision 1.7 - 16 -

7 Liftgate Preparation

Step 3 is best done while the liftgate is suspended. It is recommended to use a forklift or crane to hoist the liftgate. (Reference the “Positioning Liftgate” section on next page). Never position any portion of body under liftgate.

Steps:

1. Remove Shipping Ties: Remove shipping ties from all electrical harnesses and secure so they do NOT

interfere with liftgate positioning or welding processes.

2. Mark Centers: Mark the center of the liftgate as well as the rear sill as reference points for alignment in

later steps. An Alternative method for centering the liftgate is explained on the next page. Reference

Step 5 in the Gate Installation section on page 17.

3. Remove Lower shipping feet: Lower shipping feet may have to be removed for installation on some deep

sills.


Revision 1.7 - 17 -

8 Gate Installation

8.1 Hoisting the Liftgate

Before positioning the liftgate; consider when measuring and centering the liftgate that the truck or

trailer may NOT be square or parallel. Special care must be taken to ensure that the liftgate is square

and parallel before welding. Always disconnect the battery from the truck/trailer before welding to

avoid damage to the electrical system.

Steps:

1. Level Truck: Truck should be on level and even ground. Uneven ground will give misleading

measurements and can cause body twist or racking.

2. Make sure the liftgate is properly secured: Take a moment to check that the liftgate is attached safely to

the lifting device. To keep the liftgate from sliding back towards the forklift use 4”x 4” x 24” wood

spacers (See Figure 8-1 on next page). This will help force the top of the liftgate tight against body for

welding.

4. Fit Liftgate Against Truck: Hoist the Liftgate; preferred method for lifting liftgate is with a forklift. Position

forks to widest point and lift from center. Be sure not to damage liftgate while lifting by applying too

much force on the alignment bars.

5. Center Liftgate:

Method A: Align the liftgate so that it is centered on the truck. Use the center marks as a

reference for this step. 12” or larger “C” or “F” style clamps can be used to coach or hold the liftgate in

position.

Method B: An Alternative method for centering the liftgate is to measure side clearances from

the outside of the liftgate to the outside of the body. (Centerline marked on sill is NOT easily visible, but

can still be used as a reference.)

6. Verify Position: Confirm all mounting dimensions are correct, double check that floor and threshold

extension are flush. Securely clamp the liftgate to the truck/trailer and do not remove the lifting device

yet.

Never remove lifting device until liftgate is fully welded.


Revision 1.7 - 18 -

Floor/Bed Height

90°

Forklift Not Shown

Support Channel

Forks

4x4x24 Wood Block

Figure 8-1: Liftgate hoisted into position with forklift


Revision 1.7 - 19 -

8.2 Check Liftgate Dimensions

Steps:

1. Check Dimensions: Inspect liftgate to be certain it is square and parallel. Use a 3 ft carpenters square.

Verify columns are 90 degrees to sill or body.

2. Use “Dim A” and “Dim B” to verify columns are parallel.

3. Use “Dim C” and “Dim D” to verify columns are square.

DO NOT WELD until all dimensions are checked and rechecked after each positioning adjustment.

Dim "A"

Dim "B"

Dim "C"Dim "D"

Figure 8-2: Liftgate Dimensions


Revision 1.7 - 20 -

8.3 Welding Liftgate

Before Welding:

• Do not position hands, feet, or any other body part underneath the liftgate until installation is complete.

• Disconnect all battery cables before welding to prevent possible damage to the trucks electrical system.

• Do not remove clamps or lifting device until the gate is welded.

• Never weld at the location of the slide pads, which are connected to the runner (See figure below)

Side View

Slid

e P

ads

Runner

Towards Front of truck

Rail Cap

7"

27-3/4"

Mount Plate

Figure 8-3: Liftgate Welding Areas, Side View. Liftgate shown in shipping position.

Steps:

1. Outside Welds: If your gate came equipped with Rail Caps, remove them before welding. Using 3/16” x

2” welds, place one weld ½” from the top of each column on the outside and place one weld at the

bottom of each mount plate. Never weld at the same location as the slide pads. (See Figure 8-3

above)

STOP and recheck all mounting dimensions.

Step 1

Welds


Revision 1.7 - 21 -

2. Open and Lower Liftgate: After the gate has been properly welded in step 1, supply temporary power to

the liftgate using a 12-Volt battery source. Open the platform and then lower the liftgate to the ground.

Once opened and lowered, disconnect the temporary battery. This will allow space to finish welding,

and move the slide pads out of the way of heat from welding.

3. Inside Column Welds: Weld inside of columns using 3/16” x 2” welds in 4 places evenly spaced top to

bottom.

4. Inside Floor Welds: Weld inside of floor using 3/16” x 2” welds in 5 places evenly spaced left to right.

5. Final Outside Welds: Finish welding outside of columns using 3/16” x 2” welds in 5 places evenly spaced.

6. Attach End Caps: Once the liftgate has cooled to touch, reattach the end caps to the top of the columns

(if applicable)

Outside Column 3/16” x 2” weld 6 places as shown.

Inside Column 3/16” x 2” weld 4 places as shown.

Inside Floor 3/16” x 2” weld 5 places as shown.

On “Power Closing” liftgates, inside hose guard must be removed for proper welding of inside of column. Take special care not to burn hose.

On each side place (2) of the Outside Column welds at the upper and lower end of the mount plate. Take precautionary measures to ensure that the mount plates do not toe-out due to welding.

Figure 8-4: Weld Locations


Revision 1.7 - 22 -

8.4 Column Modification

If the columns are too long, they will need to be shortened to provide adequate ground clearance.

Remember, the maximum distance from the ground to the bottom of the track is 18”.

Steps:

1. Measure Height: With the liftgate in its highest position, measure from level ground to bottom of the

column. Consider ride height at the vehicle’s max load capacity, as well as dry unloaded ride height.

2. Mark Cut Line: Mark where the columns should be cut.

3. Cut Column: Cut the excess length of the column. Deburr after cutting by grinding the inside and outside

edges smooth. Chamfer the inside edge at 45ox1/8”.

Track

MaximumGround Clearence 18"

Add diagonal bracingto column if desired

Optional: If desired, diagonal bracing can be connected to the rail and underside of the truck/trailer body

for added strength or aesthetic purposes as shown in the figure above. Diagonal supports are not

required. Follow step 4 for instructions.

4. Add Diagonal Support (Optional): If desired cut an appropriate length of metal at 450 on both ends. If

necessary, use ¼” thick plate to bridge the gap between two body sills. The Lifting bar from the

liftgate‘s shipping stand can be cut and used for bracing.

Deburr edges from track that have been cut with a 45ox 1/8” inner chamfer.

Do not put grease or penetrating lubricants on rails or runners


Revision 1.7 - 23 -

Upper Mounting

Position (4 long rivets)

Lower Mounting

Position (4 short rivets)

Sleeve (3 short rivets)

Figure 8-6: Bracket Mounting

8.5 Installation of bracket for Control Unit

Steps:

Disconnect liftgate power cable at battery. Liftgate should be in stored position.

1. Mount Bracket for Control Unit: Mount the bracket control unit at liftgate column (curb side) with four

rivets. For trucks with a bed height of 46” to 54” use the lower mounting position and short rivets. For

trucks with bed height of 46” of less use the upper mounting position and long rivets (see Figure 8-6

below). Install rivets with a rivet gun.

2. Install Control Unit: Install the control unit to the bracket. The cable should face towards the ground.

Mount with a bolt at the bracket.

3. Install Cable Sleeve: Install the cable sleeve at the column with short rivets. For higher bracket position,

use three upper holes provided. For lower bracket position, use the lower three holes (see Figure 8-6

below).

4. Connect Battery: Connect the battery cable.

5. Operate: Briefly operate the liftgate to check functions.


Revision 1.7 - 24 -

150 AMP Resetable Breaker

RES

ET

Test

9 Electrical Installation

When performing electrical installation, please be certain to install and secure everything in a

way where it is not subject to damage from moving parts, sharp edges, exhaust systems, fuel

lines, etc. It is recommended to use dielectric grease on all electrical connections.

9.1 Main Power Connections

Steps:

1. Verify Equipment: Check for 2 gauge ground cable or heavier connecting truck batteries to chassis. If

NOT supplied by the manufacturer, one will need to be installed. Be sure to grind off paint or under

coat and seal.

2. Route Battery Cable: Route battery cable to truck batteries and secure with clips and ties supplied.

Recommended Cable Routing for Trucks

Body Stringer

Sub Wood

Truck Frame

Cable Staples

Route Cables to OUTSIDE of U-Bolts

For trailer installation refer to trailermanufacturers recommended routing

Battery Cable

2 Wire Control Box Power Cable

4-Wire Control Cable

Figure 9-1: Recommended cable routing for trucks

Never secure cable in a way where it can make contact with other wiring, brake fuel or airlines etc. or get pinched against other objects.

3. Install Circuit Breaker: Install 150 amp circuit breaker at battery location and use 12” cable to connect to

positive terminal.

Basic wiring diagrams are provided on the following pages.


Revision 1.7 - 25 -

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Cerritos, CA 90703

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9.2 Basic Wiring (Manual Closing)

Figure 9-2: Basic Wiring Diagram (Manual Closing Liftgate)


Revision 1.7 - 26 -

12/2

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15939 Piuma Ave.

Cerritos, CA 90703

888-774-5844

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9.3 Basic Wiring (Power Closing Liftgate)

Figure 9-3: Basic Wiring Diagram (Power down


Revision 1.7 - 27 -

10 Lubrication

When kept properly lubricated, the PALFINGER ILM liftgate will ensure long lasting usage. Therefore, the liftgate pivot points should be lubricated at the same time as the truck/trailer. Lubricate more frequently if the lift gate is heavily used or whenever the pivot points appear to be dry. Average ILM plus use is considered 15 cycles per day or 1200 cycles per quarter.

DO NOT grease or apply penetrating oil to the “Slider Bearings” or “Columns” or “Runners”, as this will VOID your WARRANTY on the slide bearings. There are 4 grease fittings to maintain. Grease pivot points as shown in Figure 10-1 below. DO NOT use lubrication grease to lubricate the rails. Manual Closing Gates: Use a light penetrating oil on closing aids; left & right side, upper & lower gas spring mounting points. Power Closing: Grease upper & lower pivot mounting points. Under normal use and conditions, the lifting roller chain will require minimal lubrication or maintenance as it is impregnated with good quality grease and only makes contact with Polymer sprockets. In extreme environments, should roller chain show signs of drying or rust, lubricate with a good quality penetrating type “chain lube”.


Revision 1.7 - 28 -

Lubrication Locations: All bearing points must be lubricated in accordance with the maintenance interval.

Lubricating grease nipple (1 on each side) Oil level in the power pack tank (see marking inside of power pack reservoir)

Platform hinges and optional Cart Stops (use a penetrating oil/spray for lubrication)

Figure 10-1: Grease Points, General View:

Do not put grease or penetrating oil on rails or runners. This will void warranty


Revision 1.7 - 29 -

11 Cycle Test and Final Inspection

11.1 Cycle Test and Bleed the hydraulic system.

Improper use of the liftgate may result in serious injury. DO NOT operate this liftgate without

being properly instructed and fully understanding the Owner’s manual. Platform may crush or

pinch. Make certain area around liftgate is clear during all times of operation.

No bleeding of hydraulic system is required. System is a self-bleeding system and is pre-bled

from the factory. Test steps a minimum of five (5) times each to ensure NO unusual noises or

movements are found. This will confirm all controls work correctly and hydraulic system is

completely bled of air.

POWER CLOSING Operating Instructions

Switch Operations for “Power Closing”

• “UP” switch raises platform from ground to bed.

• “DOWN” switch lowers platform from bed to ground.

• “SHIFT” + “UP” closes platform from loading position to stored position.

• “SHIFT” + “DOWN” opens platform from stored position to loading position.

Storage and Transit Position “Power Closing”

• Platform is closed and stored UP tight into the storage latch with hydraulic power.

• Pad lock is used on safety latch to prevent unauthorized use.

• Never release platform on to safety latch. This latch is for EMERGENCY situations ONLY.

Platform from Stored Position to Loading position “Power Closing”

• Be certain all pinch points and areas around platform are clear before operating liftgate.

• Hold safety latch to the open position and push “DOWN” button until platform clears storage latching

system.

• With platform clear of latching system, hold “SHIFT” button & push “DOWN” button to open platform to

loading position.

Platform from Loading Position to Stored Position “Power Closing”



Revision 1.7 - 30 -

• With platform in the loading position, hold “SHIFT” button & push “UP” button until platform touches

striker pads.

• With platform folded up and touching striker pads, push “UP” button until platform is powered tight into

storage latch.


MANUAL CLOSING Operating Instructions

Switch Operations “Manual Closing”

• “UP” switch raises platform from ground to bed.

• “DOWN” switch lowers platform from bed to ground.

Storage and Transit Position “Manual Closing”

• Platform is closed and stored tight into the storage latch with hydraulic power.

• Pad lock is used on safety latch to prevent unauthorized use.


Platform from Stored Position to Loading position “Manual Closing”


• Hold safety latch to the open position and push “DOWN” button until platform clears storage latching

system.

• With platform clear of latching system, and positioned to firmly grasp ramp end, pull platform towards

ground.

Platform from Loading Position to Stored Position “Manual Closing”


• With platform in the loading position, and positioned just above knee height, firmly grasp ramp end and

pull up closing until platform touches striker pads.

• With platform folded up and touching striker pads, push “UP” button until platform is powered tight into

storage latch.



Revision 1.7 - 31 -

11.2 Decal Placement and inspection

For operator’s safety, all decals appearing in “Decal Kit” must be placed visibly on control side of liftgate to be read by operator. This is typically a combination of decals on the liftgate and truck body. Please make sure to place the maximum capacity decal (C) on driver and curb side. (A) 1 ATG-OPERILM MC/PC - Operating Instructions

(B) 1 ATG- SWILM MC/PC - Main Operation Switch

(C) 2 ATG-XXXX - Max. Capacity (please check the serial number plate to find out your specific capacity)

(D) 1 ATG-URGWA - Urgent warning: Elevating gate instructions

(E) 2 ATG-WLH - Warning: liftgate can crush

(F) 2 ATG-PLAT - Caution: Always stand clear of platform area

(G) 1 ATG-RESET - Circuit Breaker Protection

(H) 1 ATG-BKR - Circuit Breaker Reset (must be located at the circuit breaker)

(J) 1 ATG-CAB - Liftgate Shut-Off (must be placed next to the Shut-Off Switch)

(K) 1 ATG-UD - Toggle Decal (only if applicable)

(L) 1 ATG-ILMSTORAGE – Storage Latch

(M) 1 Conspicuity Tape (If Applicable)

(N) 2 85-0713-100- Do Not Grease

Decal A

Version A

Decal – B

Version B

Decal - C

Decal - G

Decal - H

Decal - J

Decal - F

Decal - L

Decal – B

Version A

Decal – A Version B

Decal - K

Decal - E

Decal - D

Decal - M Decal - N


Revision 1.7 - 32 -

Decal B

Decal C (at both sides)

Decal A

Decal G

Decal D

Decal E (at both sides)

Decal L

Decal F (at both sides)

Figure 11-1: Decal Placement Guideline

Decal H - By circuit breaker at batteries Decal J - In the cab or at On - Off at rear

Decal N (at both sides)

You may obtain free replacement decals by calling PALFINGER Liftgates at 888-774-5844. Please have

your liftgate model # and serial # ready.


Revision 1.7 - 33 -

It is the installer’s responsibility to determine the proper application of the Conspicuity tape, and to ensure that the vehicle or trailer meets DOT and federal lighting regulations. The following diagram is a guideline for placement on trailers over 80” wide and GVWR of 10,000 Lbs or more. This document is not intended to replace published agency regulations, and it is strongly recommended that the installer refer to the Code of Federal Regulations (CFR) which can be viewed at http://ECFR.gpoaccess.gov.

H Dimension: 15”< H <60” from ground to center of tape

Requirement 3: Red/white reflective tape applied across the entire width of the rear underride protection device. Note: Not required if no underride protection is equipped

Requirement 2: On each corner: Two 12” long white reflective pieces, place adjacently to one another as close to the upper corner of the trailer as possible

Requirement 1: Red/white reflective tape applied across the entire width of the trailer placed at an appropriate height H from the ground

H


Revision 1.7 - 34 -

11.3 Final Inspection Check List

Liftgate failure or malfunction could result in property damage, personal injury or death if you fail to

check each of the following items listed. DO NOT USE the liftgate if any of the following points are

NOT verified and checked.

Installation is NOT complete and all WARRANTIES are VOID if you have not checked and verified all items listed on this inspection sheet. Inspection sheet is to be filed at the facility where liftgate was installed. Structural Inspection

� Lifting bar and shipping feet are removed from the liftgate.

� All welds are 100% complete per this manual.

� All nuts, bolts, mounting hardware, pins, chain anchors are tight.

� All mounting dimensions are correct and liftgate is square and parallel per this manual. Hydraulic Inspection

� Pump reservoir is filled to 1.5" from top when platform is opened and on the ground.

� Hydraulic components and connections do not leak. (Should be checked after unit is hydraulically locked for five (5) minutes.)

� All hydraulic lines are secured with cable ties, hoses clamps, or other fasteners. Electrical Inspection

� Battery cable(s) attached and clamped tight and dielectric grease is used to seal all connections. � All electrical lines are secured with cable ties, hoses clamps, or other fasteners. � Circuit Breakers installed and wired per instructions. � Lights wired properly and operate per DOT, State, and Federal requirements. Operational Inspection

� All decals are in place and legible per instructions. � All pivot points are lubricated per instructions. � Platform secures properly in its stowed position latches. � Platform powers UP and locks hydraulically in latches.

� Platform travels up and down smoothly and freely, without any hesitation or unusual noises.

� Platform is level with the floor of the vehicle when raised completely. � Platform rests on the ground evenly when lowered completely. � Platform opens and closes properly and at correct speed. (2 to 4 inches per second) � The liftgate serial number and model number are documented on the inside of the front cover of the Owners Manual, in the space provided. � Owners Manual is in the vehicle's glove box. � Supervisor has demonstrated the instructions in the Owners Manual to the customer/driver upon delivery.

� Gate is properly lubricated as explained in chapter 10, Lubrication. Inspection Information: Name (please print): ____________________________________________________________ Completed by: ________________________________________________________________ (signature) Title: ______________________________________________ Date: _____________________

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