90-0415-000 ILK18 IM v1.0 0415 · TABLE OF CONTENT ILK-18 INSTALLATION MANUAL Revision 1.0 - 3 -...

ILK-18

INSTALLATION MANUAL & CHECK-OFF SHEET

ECN-M0578 Rev. 1.0, Date 04-06-15 Part #90-0415-000

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

TAB

R

TaTab

1

2

3

4

5

6

7

8

BLE OF CONT

Revision 1.0

able of coble of conte

Impor

Dimen

2.1

Chass

3.1

3.2

Gate a

4.1

4.2

4.3

4.4

4.5

4.6

4.7

4.8

Electr

5.1

5.2

5.3

5.4

5.5

5.6

Lubric

6.1

Check

Instal

8.1

8.2

8.3

8.4

TENT

0

ontent ent ..............

rtant Notes:

nsion Sheet

Installatio

sis and Bod

Flip-Up d

Swing do

and Platform

Sill Prepa

Installatio

Platform

4.3.1 A

4.3.2

Installatio

Setting a

Setting a

Installatio

Finalize I

rical Installa

Main Pow

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Remote H

Wiring Di

Connecto

Hydraulic

cation and

Decal Pla

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assis, 2014

K-18 INSTAL

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ANUAL

- 2 -

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TABLE OF CONTENT ILK-18 INSTALLATION MANUAL

Revision 1.0 - 3 -

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 Heat Gun or Equiv.

Min. 250 Amp Welder Cutting Torch or Equiv.

1 Im

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1

1)

2)

3)

4)

5)

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Revision 1.0

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15. Refer to

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ANUAL

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1 Important Notes: ILK-18 INSTALLATION MANUAL

Revision 1.0 - 5 -

Mounting Notes:

Read and clearly understand manual BEFORE beginning ANY work

Important!!!

The basic rule of PALFINGER Liftgates’ ILK 18 installation is to raise mount frame

to achieve MAXIMUM ground clearance WITHOUT exceeding Min “F” dimension.

Refer to mounting tables and determine the proper [S] dimension. If the sill is greater than what’s allowed, the sill has to be notched and capped to achieve original strength. Bend flat stock and weld 100% around the notch.

Warning 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

2 D

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ANUAL

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K-18 INSTAL

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CTruck

ANUAL

- 6 -

A= B

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2 Dimension Sheet ILK-18 INSTALLATION MANUAL

MANUAL

Revision 1.0 - 7 -

2.1 Installation Dimensions ILK 18

IMPORTANT:

Always use the smallest F-dim possible for best ground clearance (don’t exceed max. ground clearance!)

K-Min 23.5" (at max F)K-Max 29" (at min F)

F-M

in 1

7.5"

F-M

ax 2

3.5"

Rear sill notchingNo Cut out required on 4.375" body rear sill height or less

cut out widths* without platform rollers - ** with platform rollers

* 7"**11"

* 7"**11"

44.5"

S

Max ground clearance 19.5" (never exceed max)Min ground clearance 14"Ground clearance = bedheight-F-3"

Min

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Figure 1 ILK 18 680 mm arm mounting dimensions

Figure 1 ILK 18 mounting dimensions

Part number for ILK 18 Mounting Fixture: 1-00015

MINIMUM bed height is defined as truck/trailer loaded to MAX GVW

3

R

3

3.1

R

1/2

Chassis and

Revision 1.0

Ch

Fli

1. Install ½”

Rear Lower Body S

2" x 1-1/2" HR Flat

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” x 1-1/2” HR

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ANUAL

- 8 -

TIRE

3 Chassis and Body Preparation ILK-18 INSTALLATION MANUAL

Revision 1.0 - 9 -

6"

Off-set approx. 1" to the rear

Set distance so gas strut is fully extended when door is open

Rubber Hinge Seal

Approx 2"

Face Piston indown position

2. Install gate per instructions per 4.1

3. Install gasket channels on rear vertical body posts to match width of platform

4. For full door seal kits install gasket channel along header at edge of platform

Figure 3 Flip-Up door

5. Apply Silaprene (or equivalent) to gasket channel and slide gasket into channel

6. Trim gasket flush with channel and crimp channel slightly at top and bottom to lock gasket

7. Install flip-up door

8. Verify Hinge Seal is approximately 3/16” above top hinge and even before tightening any fasteners

Open door several times before tightening any top hinge fasteners

9. Install lower gas strut mount so that gas strut is fully extended when door is open

10. Lower gas strut mount should be off set (approx. 1”) to the rear of body to pull door in when closed

Flip-Up door

Platform tip

Rear body post

3 Chassis and Body Preparation ILK-18 INSTALLATION MANUAL

Revision 1.0 - 10 -

3.2 Swing door applications

A bridge kit is recommended for the usage of an ILK 18 liftgate behind swing doors. Due to the shifted pivot points all welding and cut out points have to be shifted accordingly.

3" Channel (Bridge Kit)

Notch Channel To Clear Door Latch Hardware

Top View

Side View

Full Weld (Weld to Arm ONLY)

Bridge Kit Detail

1/2"x2" HR Flat

3"x4.1 Channel

When using 3" channel bridgeinstall liftgate so platform is 3-1/2" to 3-3/4" from door gasketwhen door is closed

CL

Figure 4 Bridge kit for swing door application

Please consider your particular door frame. Set up for best solution for your application.

4

Re

4

4.1

4.2

Gate and Pl

evision 1.0

Ga

Refer to

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ANUAL

- 11 -

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4 Gate and Platform Installation ILK-18 INSTALLATION MANUAL

Revision 1.0 - 12 -

5. With the mount tube held in place, position the mount plates over tube and against truck frame. As

most Truck makers require chassis specific mount plates make sure you have specified the truck make and body lengths you are mounting on as well as using the correct mount plates and chassis holes for the installation

14 mm fasteners need to be torqued to 140 foot/lbs

MB Sprinter - Mount plates 08-531.65-00.00-00 Ford Transit - Mount plates 08-531.69-00.00-000

Figure 7.2 Mount frame with MB and Ford Mount plates

Before tightening down the mount plates to final position, check that liftgate is balanced and not binding in mounting fixture, you should have equal pressure on each lift-arm pin. This is very important to make platform align with truck sill.

Cover power pack before any welding. IMPORTANT!!!!!!

6. The reservoir is made of plastic and you will burn it while welding. Make sure hoses and cables are covered if you need to do any welding for the installation of mount plates

Figure 8 Cover power pack

7. The ILK 18 was especially designed for the wide frame Panel Van Chassis, all these chassis has

pre-determined hole patterns for installation of the mount plates

Before finishing the install we recommend doing the electrical installation (see 5, Page 21) and platform installation (see 4.3, Page 13) to make sure that everything aligns like it should.


Revision 1.0 - 13 -

Figure 9 Bolted mount plates (picture shows Ford Transit)

Before running the unit through its cycle, make sure that the In-Cab Switch is in the “ON” position (lights on) Before running the unit through its cycle, make sure that the solenoids on the lift cylinders are not hitting the mount plates or Chassis items

4.3 Platform Installation

If power pack is still removed from mount tube for welding, reconnect the ground cable and pow-

er connection. Do not push back in, welding is not finished!!!!!!

Attention: check all PC-Board connections for tightness

4.3.1 Attach platform to liftarm

1. Remove pins attached to mounting fixture and lift arm. Lift arm will drop about 12”- 16”.

2. Remove mounting fixture from truck bed

3. Lower lift arm to ground to bleed air out

4. Support platform horizontally with forklift, overhead crane or similar equipment

5. Install platform onto lift arm using small pins.

6. Tighten up pin lock bolts


Revision 1.0 - 14 -

4.3.2 Installation and Adjusting the tilt cylinders

Pin only one cylinder at a time to the platform

Figure 10 Attaching of platform with tilt cylinders

1. Tilt platform up to a point of easy access of the tilt bushings (using the forklift, overhead crane, etc.)

2. When installing the tilt cylinder into the platform, extend the tilting cylinder by pressing the switch for opening and closing until the pins fit in the tilt cylinder and the platform bushings. For this purpose, hold the platform sensor B-16 with the cable straight down.

3. For the platform to be in the required end position, the tilting cylinder must be fully extended

4. Verify that reservoir breather cap is installed and hydraulic fluid is at proper level with platform on the ground

Make sure to tighten the tilt piston rod lock nuts when you are finished.

Wrench Sizes for Tilt Cylinder Adjustments

Gate Model Nut Piston ILK 18 29MM 29MM

How to adjust the tilt cylinders:

1. Raise the gate all the way up against the truck body.

2. Close the platform – tilt cylinders fully extended.

3. Look for a gap at the platform tip and the body.

4. If platform is not completely in a vertical position, open up platform about 15-20 degrees and lower down about 5”-10”. Adjust the tilt cylinders by rotating the piston in the cylinder head.

5. Repeat step 4 till platform is vertical and even with body

6. Tighten left and right lock nut at tilt piston to keep

Ideal position: 45 degrees


Revision 1.0 - 15 -

Round side of tilt cylinder clevis MUST face down towards ground

Lock nut to be tightened when platform is in vertical positionRound shape of clevis towards the ground

If you have not finished the welding, carefully run lift to see if it is properly aligned with the floor sill, remove pump & motor from tube and finish all welding work before continuing with detail work.

Never power the lift hard against anything if you have not finished welding.


Revision 1.0 - 16 -

4.4 Installation without mount fixture

1. Connect platform to lift arms using short pins

2. Tie tilt cylinders with rope or wire to lift arm to avoid dragging on the ground

3. Support platform with forklift, overhead crane or similar device

4. Lift platform up and support mount tube with rolling floor jack or similar device

5. Slide platform/mount tube assembly under the vehicle frame

6. Set platform so it is centered level and flush with body floor

7. Secure and attach platform to body using 3” channel or equivalent with tack welds (steel platform) or clamps (aluminum platform) to assure level position of platform to body floor (shown in Figure 4.3)

Warning: Never work or place yourself under unsupported Platform

8. Place the mount tube in the predetermined position, keeping the given maximum and minimum F- and K-Dimensions in mind. Use floor jack or a similar device to position the mount tube. Make sure that you place the tube at a 90-degree angle to the truck bed.

Figure 4.11: Platform install without fixture

9. When mount frame is in place, tack weld mount plates to mount tube with minimum three 2” welds and three 2” welds to the frame.

10. Before finishing all welding we recommend doing the electrical installation (see chapter 5 on page 21) and to make sure that everything aligns like it supposed to be.

11. Remove the 3” channel and follow instructions to install tilt cylinder as shown in chapter 4.3.2

Install gate at maximum ground clearance.


Revision 1.0 - 17 -

4.5 Setting and Operation of B-16 Sensor

1. Mount the platform sensor B-15 to the right-hand side of the platform as shown in Fig.4.4. Make sure to loop wire around to give it enough slack in normal operation and route clear of any pinch points.

2. Close the platform as much as possible to body of vehicle. (Tilting cylinder is fully extended). Relieve tilting cylinder pressure with the ‘tilt open’ switch. Adjust the platform to required vertical po-sition by turning the piston rod in or out of the clevis using a wrench (See page 14). Repeat the set-ting procedure if necessary. It is important that both of the cylinders are adjusted equally.

3. Verify that the platform sensor B-15 is set correctly by placing platform in stored position (fully verti-cal) and check that warning lights are off (with cab switch off). If lights still on when gate is stored, loosen the 5mm x 50mm Allen Head mount screws at sensor and rotate slightly till lights turn off. Re-tighten screws

Figure 4.12: B-16 Sensor and warning light cable installation and placement

Warning Light/Foot Control (option) MUST have all connectors tied off and inserted into platform profile after connections are made. Route cables secure to avoid damaging harness during regular operation

Assure that B-15 sensor is installed with a service loop so cable does not get damaged during full cycle of platform. With platform in vertical position the wire is point-ing straight down, parallel to the platform surface.


Revision 1.0 - 18 -

4.6 Setting and Operation of B-13 Sensor

1. Raise platform approx. 8” – 10” off ground and verify platform is level (tilt if necessary)

2. Loosen lock bolt and set sensor level with platform surface/ground (verify colored side of sensor is out, plastic housing is facing to lift arm)

3. Lower platform to ground. When properly set, platform should remain level for approx. 2 seconds, then tip will tilt towards ground.

4. Cycle Platform from bed height to ground several times to verify proper operation. Tilt sensor slightly forward or back to achieve proper Auto-Tilt action.

Lift Arm

Lift Cylinder

B-13 Sensor

Tilt Cylinder

At NO time should the platform tilt towards ground while lowering. Platform should ONLY tilt AFTER Lift Arms/Nylon Rollers contact ground.

5. After sensor is properly set, tighten lock bolt to 43 in.lbs/3.5 ft.lbs

6. Cycle platform several times to check operation after tightening.

7. If Platform does not level, but lifts up only, check batteries, start truck in fast idle.

8. Fold down Lock Tab tightly onto Lift Arm (see above)

Never over torque B-13 lock bolt.

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.

8"-10"

Sensor horizontal in this position

B-13


Revision 1.0 - 19 -

4.7 Installation of left and right Up Stops

Weld to C/M's

Weld to Stringer

Suggested Stop #2

Suggested Stop #1

Damage to the body may occur if up stops are not installed properly

How to install the Up-stop:

1. Raise platform up to rear sill verifying it is level with body floor and there is a slight gap (appr. 1/8”) between lift arm and rear sill.

2. Determine type of up stop for your installation. 3. Set up stop so that it makes contact with liftarm. 4. Tack weld in place. 5. Cycle gate to verify liftarm makes contact with left and right up stops before making contact with rear

sill. 6. There is not an excess gap between rear sill and liftarm 7. Platform is level with body floor.

Install the liftarm up stop so it is positioned in a way that it stops the liftarm when the platform is level with the floor of the truck


Revision 1.0 - 20 -

4.8 Finalize Install

If any welding is required for sub frame or mount plates Protect all wires from dropping slag or splatter when welding mount plates.

1. Verify the platform is in the correct position in relation to truck sill.

2. If a bolt on installation is not possible due to different chassis set up-Weld mount plates to chassis/ body subframe with a min of 2 x 12” x 1/4” fillet weld around mount plates and chassis/body long sill

3. PALFINGER Liftgates recommends adding 3/16” flat bar or plate to the top of mount plates if need-ed to tie Liftgate mount plates to body stringer.

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Only)

-

Liftgate M

Ground

-

n

ound

tteries cable)

yr

able)

-

e Cableys wire to tructo aux. battery

In-Fu

ILK

nstall and sehaust system

e battery an

me to battery

.

+-

Mount F

+-

+-

k batteryy

-Lineuse on #2 and #27

K-18 INSTAL

ecure everytms, etc.

nd control b

y.

Frame

2G

aLi

ftgat

eP

ower

Cab

le

CircuitBreaker

LLATION MA

thing in a w

board at the

Gro

und

Cab

le

Groun

2 G

a. L

iftga

te P

ower

Cab

le

Motorsuppl

Contpow

ANUAL

- 21 -

way where it

e pump

nd

r power ly

trol board wer supply

5 Electrical Installation ILK-18 INSTALLATION MANUAL

Revision 1.0 - 22 -

FOLLOW DOTTED LINE IF ISOLATOR OR AUXILLIARY BATTERIES INSTALLED!

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. Never run wiring next to fuel hoses or attach to it.

Breaker Installation (Fig. 5.1)

1. Mount circuit breaker securely in battery box 2. Connect liftgate 2Ga. cable to open stud on circuit breaker 3. Connect 2Ga. jumper from forward most stud on breaker to positive battery post

Figure 5.1: Circuit Breaker installation

Mount circuit breaker securely in battery box or at positive battery post using supplied buss bar Connect liftgate 2Ga. cable to open stud on circuit breaker Connect 2Ga. jumper from open stud on breaker to positive battery post if circuit breaker was not

mounted straight at battery with buss bar

1. Determine location for fixed control box; locate it in a way that the operator can view the platform and surrounding areas while operating the liftgate. Also, locate in a way where the lid does not ex-tend outside the van body when open.

150 AMP Resetable Breaker

RESET

Connect 2 Ga cable coming from lift gate

Connect here to Positive Battery post

Suggested mounting dimensions


Revision 1.0 - 23 -

5.2 On-off switch installation

Install the cab shut-off switch inside the cab. Locate it where it can conveniently be seen and reached from the driver’s seat as well as from the ground.

Place cab shut off in view of the driver and within reach from the ground.

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

2. Lead the 4-wire cab switch together with the battery cable and the 4 wires for the control power to

the batteries along the sub-wood. Secure the cable every 12 inches against the sub-wood with cable staples. Run only the cab switch into the cab. Battery cable and 4 wire control power cable will go directly to the truck battery. (#2 and #4 go to positive post with an inline 20 amp fuse; #1 and green/yellow go to negative post)

In-Cab Cut-Off Switch (For Truck Use Only)

Green/Yellow (-)

White (#1)

Blue (BS3)

Red (#2)

Blue (#4)

"Off" Symbol

In-Cab Switch Color and Number Coding

Cable wires are marked: Cab Cut off Switch Code 1 = Hot Lead To Red L.E.D. Lights - WHITE (-) = Ground To L.E.D. Lights - GREEN YELLOW 2 = 12 Volt Power - RED 4 = Control Power To Liftgate - BLUE


Revision 1.0 - 24 -


Revision 1.0 - 25 -

Inspect and test all electrical connections, wiring and the different functions to make sure that the electrical installation is complete.

5.3 Remote Hand Control Installation

Hand Controls are NOT weatherproof and have to be stored inside body in holster or in weatherproof box (PALFINGER Liftgates option). For “Refer”- & Flatbed Installations or stored in cab solutions we recommend “plug & socket” option.

1

2

Hand Control Holster

Mount Holster inside body on curb side at rearMount approx. 40"-48" from floor (end user needs may very)

BUTTON NO. 1 – UP BUTTON NO. 2 + 1 – TILT CLOSE BUTTON NO. 2 – TILT FUNCTION ACTIVATION BUTTON NO. 2 + 3 – TILT OPEN BUTTON NO. 3 – DOWN

Connect all wires together according to cable ID’s. Use heat-shrink to seal the connection.

3 Button Hand Control

Function From H/C / Color From Gate / Number

Up - 5.2 / Yellow 5.2 - #4

Down - 6.2 / Brown 6.2 - #3

12V Hot - 4.3 / Red 4 – Gn/Ye

Tilt-Up - 3.2 / White 3.2 - #1

Tilt-Down - 14.2 / Green 14.2 - #2

3


Revision 1.0 - 26 -

Optional Plug and Socket application

3 Button Hand Control

#4

#2

#1

Female Receptical (Looking at Front)

#3

Green/Yellow

Figure 5.2: Plug& Socket wiring for Hand Control


Revision 1.0 - 27 -

5.4 Wiring Diagrams

war

ning

lig

ht

O

PTI

ON

AL

WA

RN

ING

LIG

HT

S &

FO

OT

CO

NT

RO

LS

150

Flu

sh 3

But

ton

Con

trol

WIR

LES

S H

AN

DC

ON

TR

OL

OP

TIO

NA

L

CIR

CU

IT B

OA

RD

2 G

A C

AB

LE

4 W

IRE

CA

BLE

Lege

nd :

gn :

gree

nbl

: bl

uebr

: br

own

wt :

whi

teye

: ye

llow

bk :

blac

kgy

: gr

een-

yello

w

# 2

BLA

CK

# 4

BLA

CK

# 1

BLA

CK

GR

EE

N /

YE

LLO

W

(+) (-

)

LI :

Lift

Up

LO :

Low

er D

own

OP

: O

pen

Gat

eC

L :

Clo

se G

ate

ILQ

K

1PLU

SH

AC

KB

AR

TH

159

39 P

ium

a A

ve

Cer

ritos

, CA

907

03

Figure 5.3: Electrical schematics


Revision 1.0 - 28 -

5.5 Connector Overview

CIR

CU

IT B

OA

RD

PO

WE

R P

AC

K

B-1

3 LI

FT

AR

MB

-16

PLA

TF

OR

M

GR

OU

ND

CO

NT

RO

L PA

NE

LC

AB

CU

T O

FF S

WIT

CH

FOO

T C

ON

TRO

LW

AR

NIN

G

LIG

HT

S

HA

ND

RE

MO

TE

CY

LIN

DE

RS

LIF

T 15

(2

ea)

TIL

T 14

(2ea

)

Figure 5.4: Electrical Wiring overview


Revision 1.0 - 29 -

5.6 Hydraulic Schematic

Functions:

Lift: MLower: S1+S2+S5Tilt Up: M+S5Tilt Down: S3+S4Horiz. Open: M+S3+S4

Pressure Relief

2850 PSI200 bar

Shift Valve S5

Restrictor Valve R5

Flow Divider

Functions:

S1 and S2 = Release Valve for lowering functionS3 and S4 = Release Valve for tilt down functionR1 and R2 = Flow Restrictor located inside hose adaptor on lift cylinderR3 and R4 = Flow Restrictor located inside hose adaptor on tilt cylinderS5 = Shift Valve is activated on tilt up and lowering functionR5 = Restrictor Valve located in power packFlow Divider is activated, when fluid is going back into the power packIf Flow Divider is loose or hanging up the fluid is circulated back in to tank

Figure 5.7: Hydraulic schematic

6

Re

6

Lubrication a

evision 1.0

Lu

1. Open p

2. Remov

3. Lower

4. Cycle p

5. Wipe e

6. Check

7. Paint a

N

8. Remo

9. Check

10. Re-rou

11. Lower

12. Check

13. Install

T

and Final Ins

ubrication

platform an

ve red caps

platform to

platform op

excess grea

k ALL pin lo

all welded a

Note: Do n

ve any ove

for any wir

ute and/or ti

platform co

Plugs on P

all operatio

TIRE

2

4

spection

n and Fin

d lift gate to

s, apply gre

ground an

pen and clos

ase from joi

ock bolts f

areas and a

not paint ch

erspray from

res or hoses

ie up wires

ompletely to

PC Board. P

on and safe

Figure 6.1: L

al Inspec

o bed level

ase until gr

d grease le

sed severa

ints and rep

for proper

area that ha

hrome hyd

m cylinder p

s that may

and hoses

o ground an

Push tight a

ty decals

1

3

5

6

Lubrication Poi

ction

rease begin

eft over grea

al times and

place ALL r

torque of 1

ave been sc

draulic pist

piston rods

rub during

as necess

nd slide out

and reinstal

ints (opposite d

ILK

ns to flow fr

ase zerks.

d grease ag

red caps

14 ft-lbs

cratched du

ton rods

operation.

ary

t pump/mot

ll clamp on

direction on cur

K-18 INSTAL

rom bushing

gain (Fig. 6.

uring installa

tor to check

rubber cov

rb side)

LLATION MA

g ends

.1)

ation

k oil level

ver

TIRE

ANUAL

- 30 -

6

Re

6.1

Fo

sid

sur

(A)

(B)

(C)

(D)

(E)

(F)

(G)

(H)

(J)

(K)

Lubrication a

evision 1.0

De

r operator’s

de of liftgate

re to place

) 1 ATG-URG

) 1 ATG-ILK

) 2 ATG-XXX

) 1 ATG-CAB

) 1 ATG-BKR

2 ATG-WLH

) 2 ATG-CTN

) 1 ATG-RES

1 ATG-OP

) 1 ATG-FT -

Deca

Deca

Decal -

and Final Ins

ecal Placem

s safety, all

e. This is ty

the maximu

GWA - Urge

- Main Ope

XX - Max. Ca

B - Liftgate S

R - Circuit Br

H - Warning

N - Caution:

SET - Circui

ENILD - Not

- Notice for F

al - A

al - H

E

spection

ment and In

decals app

pically a co

um capacit

ent warning:

eration (Cont

apacity (plea

Shut-Off (mu

reaker Rese

: liftgate can

Always stan

t Breaker Pr

tice for Open

Foot Control

nspection

pearing in “

ombination

y decal (D)

Elevating ga

trol Box)

ase check th

ust be placed

et (must be lo

n crush

nd clear of p

rotection

n & Close

l (if applicab

Decal - B

Dec

Dec

“Decal Kit”

of decals o

) on driver a

ate instructio

he serial num

d next to the

ocated at the

platform area

le)

al - F

al - J

ILK

must be in

on the liftga

and curb sid

ons

mber plate to

e Shut-Off Sw

e circuit brea

a

Decal

K-18 INSTAL

a conspicu

te and truc

de.

o find out yo

witch)

aker)

- C

LLATION MA

uous place

ck body. Ple

our specific c

Decal

Decal - G

Decal - K

ANUAL

- 31 -

on control

ease make

capacity)

- D

6

Re

Lubrication a

evision 1.0

Deca

of the

from

platfo

and Final Ins

al G (on the

e platform; v

outside

orm is closed

spection

back

visible

when

d)

Figu

ure 1: Deca

Deca

Deca

al Placemen

ILK

al C

al F

nt Guideline

K-18 INSTAL

e

D

O

D

at

A

fo

3”

LLATION MA

Decal A

Decal B

Decal H

Decal J

Decal K

Decal D - in t

On - Off at re

Decal E - by

t batteries

Aluminum o

or foot contro

”x4”, P-1341

ANUAL

- 32 -

the cabine o

ar

circuit brea

operation p

ol

1966

r at

aker

late

6 Lubrication and Final Inspection ILK-18 INSTALLATION MANUAL

Revision 1.0 - 33 -

"B"

2-3/4"

"C"

1/4"

"D"

5-1/4"

Palfinger Liftgates LLC15939 P

iuma A

ve.C

erritos, California 90703

may not be traced, copied or used

without the w

rittenperm

ission of Palfinger

This drawing and it's contents are

the the property of Palfinger

and

Draw

n by:D

ate:R

ev Date:

MH

4/05/15Liftgate M

ounting Fixture

56"

Model

"A"

"B"

ILK 18/22

ILK 33

ILK 44/55

"C"

"D"

44-3/4"

53-1/4"

53"1-1/2"

1-3/8"

1"15/16"

1-1/4"

1-7/16"

Correct P

lacement

ILQ 22-ILK

18/22/33/44/55/66

"A"

Inside Dim

ension

3"x3"x1/4" Angle

7/8"

1-1/4"

1-5/16"

ILK 66

ILQ 22

44-3/4"1"

15/16"

7

Re

7

Check Off S

evision 1.0

JOB NO.

GATE NO.

OWNER'S M

ON-OFF SW

WIRING

HYD. LINES

SECURED

HYD. OIL

LEAKS

WELDS

PUMP

& MOTOR

PINS

Note:This mustpresented

Ch

Sheet

MANUAL IN CAB

WITCH WORKING

1. Power Co

2. Cables No

3. 12V Contr

4. Loomed &

5. Circuit Bre

Installed &6. Loop in pl

1. No Rubbin

2. No Rubbin

3. Up-Down

4. Storing Pl

1. None At H

2. None Pow

3. Cylinders

1. Full Welds

2. Ground Of

3. Frame Ca

1. Check Flu

2. Connectio

3. Power Ca

4. Ground Ca

5. Breather I

6. Cables Tie

7. Fuses Tig

8. Clamp on

1. Grease Ze

2. Red Greas

3. Bolts Tigh4. Ground Ro

t be filled out ad to PALFINGE

heck Off S

& DECAL IN PLA

rd Secured

ot Rubbing Steel

rol Wire Secured

& Stapled

eaker & Fuse

& Decal In Placeatform sensor wire

ng On Frame

ng On Platform

Clear

atform Clear

Hoses

wer Pack

s Mount Plates

ff / Clean

apped Off

uid With Platform

ons Tight With Hea

ble Tight

able Tight

nstalled

ed Off

ht

cover

erks In Place

se Caps On Zerks

ht On Pinsollers On

and kept for yER Liftgates f

Sheet

ACE

OPER

re

FINAL

INSPE

On Ground

at Shrink

OPTIO

CHEC

s

your records. for any warran

VIN NO.

RATION 1.

o

2.

3.

4.

A5.

w6.

7.

a

8.

9.

L 1.

ECTION 2.

3.

4.

5.

6.

7.

8.

9.

10

11

ONS 1.

2.

3.

CKED BY

DATE

A copy of thisnty compensa

ILK

All Functions Op

outside Control &

Up Stops In Plac

Platform Meets B

Sensor Set For P

Auto tiltWarning lights st

when platform stoCab switch not fla

platform stored an

Platform hits rear

at the same time

Titl cylinder clevis

lock nuts tight

No Paint on cylin

Platform Touches

Lights Working O

Lic. Plate Bolts &

Decals Installed

Rubber & Plastic

Gate Painted Com

Body Clean Arou

Pin Greased - 12

Cylinders Clean

0. Clamp on cover

. Exhaust mud fla

All Options On G

Circuit Breaker T

Cart Stops Work

s sheet must ation

K-18 INSTAL

erate On

Hand Control

ce

Body

Proper

top flashing

oredashing when

nd switch off

r sill even

s

nder shafts

s Ground

On Chassis

& Lights

c Caps on

mpletely

und Gate

2 Places

aps are ok

Gate

Tight

ing

be

LLATION MAANUAL

- 34 -

7

Re

8

8.1

Check Off S

evision 1.0

Ins

Me

Sheet

stallation

ercedes Be

995 mm

1960 mm

35 mm

L 1250 mm (1350)

rear chassis overhang L

230 mm

N min.0 (550)

N min.14 (680)

330 mm

n Referen

enz, Wheel

180 mm

max.621 mm

adjustable area

loaded 655 mm

295 mm

80 mm

0 mm

ce

base 144“

1240 mm pitch dimension

width of underrun protection device

3-part=2030 mm / 1-part=1960

1086 mm mounting plates inside

2

9

-170“

ILKK-18 INSTALLLATION MA

08

531

65

00

00

00

ANUAL

- 35 -

08-5

31_65-0

0_00-0

0

7 Check Off Sheet ILK-18 INSTALLATION MANUAL

Revision 1.0 - 36 -

8.2 Mercedes Benz, Wheelbase 144“-170“

L 1263 (1113) rear chassis overhang

N min.70/235(550)

N min.154(680)

max.415 mm(285)

adjustable area

100 mm

252 mm

loaded 602 mm

80 mm

240 mm

995 mm

35 mm

1959 mm

width of underrun protection device 3-part=2030 mm / 1-part=1960



340 mm

08-5

31_67-0

0_00-0

0

160 mm


Revision 1.0 - 37 -

8.3 Ford Transit, Wheelbase 123“-156“


3-part=2030 mm / 1-part=1960

L 948 mm rear

chassis overhang

single wheel (L1-L3) 1935 mm

double wheel (L2-L3) 2047 mm

N min.344 (550)

N min.428 (680)

max.175 mm

adjustable area

128 mm

321 mm

loaded 661 mm

10 mm

250 mm

960 mm chassis / auxillary frame width



262 mm

350 mm

99 mm

08-5

31_68-0

0_00-0

0

(122 mm)


Revision 1.0 - 38 -

8.4 Ford Transit, Wheelbase 156“, Extended Chassis, 2014

single wheel (L4) 1935 mm

double wheel (L4) 2047 mm

960 mm chassis

auxillary frame width

350 mm

250 mm

103 mm

N min.0(550)

N min.45(680)

L 1332 mm (1502)

rear chassis overhang max.245

adjustable area

128 mm

321 mm

loaded 661 mm

100 mm


3-part=2030 mm / 1-part=1960



250 mm

1502

08-5

31_69-0

0_00-0

0

122 mm


Revision 1.0 - 39 -

90-0415-000 ILK18 IM v1.0 0415 · TABLE OF CONTENT ILK-18 INSTALLATION MANUAL Revision 1.0 - 3 -...

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