ilf44-55 im v1.4 0713 · 3.1 bed extension & dock bumper installation ... to med. bottle jack...

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ILF 44/55 INSTALLATION MANUAL & CHECK-OFF SHEET ECN-M0253 Rev. 1.4, Date 07-10-2013 Part #90-0813-200 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

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Page 1: ILF44-55 IM v1.4 0713 · 3.1 Bed Extension & Dock Bumper Installation ... To Med. Bottle Jack Forklift or O/H Crane Hand Held Grinder Paint Gun ... 1. Read Manual completely before

ILF 44/55

INSTALLATION MANUAL & CHECK-OFF SHEET

ECN-M0253 Rev. 1.4, Date 07-10-2013 Part #90-0813-200

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

Page 2: ILF44-55 IM v1.4 0713 · 3.1 Bed Extension & Dock Bumper Installation ... To Med. Bottle Jack Forklift or O/H Crane Hand Held Grinder Paint Gun ... 1. Read Manual completely before

TABLE OF CONTENT

Revision 1.3 - 2 -

TABLE OF CONTENT

TABLE OF CONTENT ................................................................................................................................... 2

1 Important Notes: ....................................................................................................................... 4

2 Dimension Sheet ...................................................................................................................... 6

2.1 Installation Dimensions ILF 44 and ILF 55 .................................................................... 8

3 Chassis and Body Preparation for special applications ........................................................ 9

3.1 Bed Extension & Dock Bumper Installation ................................................................... 9

4 Gate and Platform Installation ................................................................................................. 10

4.1 Sill Preparation ............................................................................................................. 10

4.2 Installation with platform clamped ................................................................................. 10

4.3 Installation without platform attached ............................................................................ 11

4.4 Adjustment of the tilt cylinder ........................................................................................ 13

4.5 Setting and Operation of B-15 Sensor ........................................................................... 14

4.6 Setting and Operation of B-13 Sensor ........................................................................... 14

4.7 Platform Installation ...................................................................................................... 15

4.8 Final Welding ................................................................................................................ 16

5 Electrical Installation ................................................................................................................ 19

5.1 Main Power Connections .............................................................................................. 19

5.2 On-off switch installation (Truck / In-Cab)...................................................................... 20

5.3 On-off Switch Trailer application ................................................................................... 22

5.4 Remote Hand Control Installation ................................................................................. 23

5.5 Foot Control installation ................................................................................................ 24

5.6 Wiring Diagram ............................................................................................................. 25

6 Lubrication and Final Inspection ............................................................................................. 27

6.1 Hydraulic Schematic ..................................................................................................... 28

7 Check Off Sheet ........................................................................................................................ 29

Page 3: ILF44-55 IM v1.4 0713 · 3.1 Bed Extension & Dock Bumper Installation ... To Med. Bottle Jack Forklift or O/H Crane Hand Held Grinder Paint Gun ... 1. Read Manual completely before

TABLE OF CONTENT

Revision 1.3 - 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.

Page 4: ILF44-55 IM v1.4 0713 · 3.1 Bed Extension & Dock Bumper Installation ... To Med. Bottle Jack Forklift or O/H Crane Hand Held Grinder Paint Gun ... 1. Read Manual completely before

1 Important Notes:

Revision 1.3 - 4 -

1 Important Notes:

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 Pin Bolts are tight

9. Grease all pivot points

10. Verify ALL Decals properly placed (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)

BED HEIGHT [H] Bed Height Ranges: Max=Unloaded / Min=Loaded Truck

• Measure from top of body floor to ground. Vehicle must be on flat level ground when measured.

MOUNT TUBE HEIGHT [F]

• Measure from TOP of Mount Tube to TOP of body floor

MOUNT TUBE [K]

• Measure from rear of body to forward edge of Mount Plate.

REAR SILL CUT OUT [S]

• Refer to H, K &S Charts and Cut Out diagrams on following pages

GROUND CLEARANCE

• Measure from BOTTOM of Mount Tube to ground

Page 5: ILF44-55 IM v1.4 0713 · 3.1 Bed Extension & Dock Bumper Installation ... To Med. Bottle Jack Forklift or O/H Crane Hand Held Grinder Paint Gun ... 1. Read Manual completely before

1 Important Notes:

Revision 1.3 - 5 -

Mounting Notes:

Read and clearly understand manual BEFORE beginning ANY work

Important!!!

The basic rule of PALFINGER Liftgates’s ILF installation is to lift mount frame

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

Refer to mounting tables and determine the proper [S] dimension. If the floor sill is greater than what’s allowed, the floor 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 MAX LOADED. 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

Page 6: ILF44-55 IM v1.4 0713 · 3.1 Bed Extension & Dock Bumper Installation ... To Med. Bottle Jack Forklift or O/H Crane Hand Held Grinder Paint Gun ... 1. Read Manual completely before

2 MOUNT DIMENSIONS

Revision 1.3 - 6 -

2 Dimension Sheet

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2 MOUNT DIMENSIONS

Revision 1.3 - 7 -

Page 8: ILF44-55 IM v1.4 0713 · 3.1 Bed Extension & Dock Bumper Installation ... To Med. Bottle Jack Forklift or O/H Crane Hand Held Grinder Paint Gun ... 1. Read Manual completely before

2 MOUNT DIMENSIONS

Revision 1.3 - 8 -

2.1 Installation Dimensions ILF 44 and ILF 55 IMPORTANT:

Always use the smallest F-dim possible for best ground clearance

(Don’t exceed max. ground clearance!)

Minimum bed height is when truck/trailer is loaded to MAX GVW

Mounting Table

F- DIM

ENSIO

N (in

ches

)K DIMENSION ( inches)

102"67"48"

Min of 8"over lap

Ground Clearance Min17"

Max 19.5"

21.5"

28

27

26

25

26 27 28 29

F-Dimension Min 25"Max 28"

Bedheight Min 50"

Max 55.5"

K-Dimension Min 26"Max 29"

Figure 2.1: ILF 44-55 Installation table

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3 Chassis and Body Preparation

Revision 1.3 - 9 -

3 Chassis and Body Preparation for special applications

The ILF liftgate will require different mounting space requirements depending on floor heights.

1. Determine the correct frame cut out according to your specific bed height (refer to Figure 2.1). With long overhangs it is even more important to maintain min F = Max ground clearance.

2. Trim rear of truck frame per Liftgate mounting table.

3.1 Bed Extension & Dock Bumper Installation

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.

3" Channel

(Customer Must Miter Per Application)

Channels Shipped W/ Sq. Ends

1" x sill depth

Interlift 16" Bumpers might need notching in some cases

3/16"

3/16"

3/16"

12"

16"

4" Channel standard to clear shackles

Figure 3.1: Bed Extension install Figure 3.2: Dock Bumper install

1. Tack weld channels or angle (2) to rear sill (not supplied) 2. Center bed extension, flush with floor. (Figure 3.1) Clamp or tack weld to channels or angle 3. Verify bed extension is centered on body and flush 4. Weld as shown in Figure 3.3

-> 3/16” x 4” welds on approximately 10” centers alternate top and bottom welds

Weld the 6 vertical braces 100% under the bed extension on unit

Do not weld across the corner posts

No weldareas

6 ea.

Figure 3.3:Bed extension weld areas

5. Install dock bumpers (available from PALFINGER Liftgates as an option) 6. If installing PALFINGER Liftgates dock bumpers refer to Figure 3.1

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4 Gate and Platform Installation

Revision 1.3 - 10 -

4 Gate and Platform Installation

4.1 Sill Preparation

1. Notch rear sill if necessary per Mount Table for your particular model 2. Box in notch with flat bar to maintain sill strength. 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.

3. Note: Refer to 3.1 before proceeding

4.2 Installation with platform clamped

1. Install Platform to Liftarm using short pins 2. Support Tilt Cylinders with rope or wire to avoid dragging 3. Support Platform with forklift, overhead crane or similar device 4. Support Mount Tube with rolling floor jack or similar device 5. Slide Platform/Mount Tube Assy in under the vehicle frame 6. Set Platform so it is level and flush with body floor 7. Secure Platform to body using 3” Channel or equivalent using clamps or Tack welds being sure to

maintain level position to body floor

Warning: Never work or place yourself under unsupported Platform

8. Place the mount tube in the predetermined position, keeping the given maximums and minimums 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.

3" channel clamped or tack welded in placeto platform and body

Warning:Never work under unsupported platform.

After securing platform swing Mount Frame to proper mount height

Figure 4.1:Platform install without fixture

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4 Gate and Platform Installation

Revision 1.3 - 11 -

4.3 Installation without platform attached

The mount tube should be placed as high as possible to achieve better ground clearance, keep in mind that this also directly relates to the mount tube clearance. Make sure that you stay within the maximums and minimums given in the mounting tables.

1. Install the bed extension first. Locate and mark out the center of the rear body or bed sill. 2. Slide mount tube in under the truck frame and attach the lift arm to the holes in the bed extension. At

this point you should place the mount tube in the predetermined position, keeping the given maximums and minimums in mind. You can use a forklift, a 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. (fig 4:3)

Be certain to pull out power tray before welding.

3. The reservoir is made of plastic and you will burn it while welding. To pull out tray, just simply remove the bolt on the curbside and detach the ground strap and control power connector for the tray. Pull on tray until the hoses are stretched and the tank is further out than the point of welding. Verify hoses or cables are not touching inside of tube wall.

Before any welding is started, check that liftgate is balanced and not binding, you should have equal pressure on each lift-arm pin. This is very important to make platform align with truck sill.

Liftarm

Align Lift arm with Bed Extension holes

Figure 4.2: Mount frame alignment with bed extension holes

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4 Gate and Platform Installation

Revision 1.3 - 12 -

4. With the mount tube held in place, position the mount plates over tube and against truck frame. Position them with angle forward and clamp them to truck frame.

5. Tack weld mount plates to mount tube with a minimum three one inch welds and three one inch

welds to the truck frame. Make sure to ground on the frame and not on the platform.

Before finishing up all welding we recommend doing the electrical installation and platform installation to make sure that everything aligns like it should.

Use a min of 8" overlap between mount plates and truck frameWeld 100% with 1/4" weld against the frame and both sidesof the plates against the mount frame

Install Lower Gusset SuppliedON 5500 LB Units ONLY

Before running the unit through its cycle, make sure that the In-Cab Switch is in the “ON” position (Lights are on)

Before running the unit through its cycle, make sure that the solenoids on the lift cylinders are

not hitting the mount plates.

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4 Gate and Platform Installation

Revision 1.3 - 13 -

4.4 Adjustment of the tilt cylinder

Tilt cylinder can only be operated, when Sensor B-13 is indicating “ Liftarm on Ground” and Sensor B-15 is indicating “Platform pulled out”. See next chapter for details.

Wrench Sizes For Tilt Cylinder Adjustments

Gate Model Nut Piston ILF 33 50MM 36MM ILF 44-55 65MM 42MM

When installing the tilt cylinder into the platform, extend the tilting cylinder by pressing the switch for opening and closing until it is possible to pin the cylinder to the platform. For this purpose, hold the inclination sensor B-15 with the cable down.

Adjust Tilt Cylinders at Clevis, so platform can be easily un-folded and stored. Loosen Lock Nut on piston, turn piston using flat areas. Clock wise to shorten. Counter Clock wise to extend. **Secure piston rod with lock nut when finished

Adjust Bolts to level platform: Secure bolt with lock nut after adjustment

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4 Gate and Platform Installation

Revision 1.3 - 14 -

Round side of Tilt Cyl. Clevis MUST face down toward ground (Detail Y)

Pin only one cylinder at a time to the platform

DETAIL Y

Lock nut to be tightened after clevis adjusted

If you have not finished the welding, carefully run lift to see if it is properly aligned with the floor sill.

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

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

4.5 Setting and Operation of B-15 Sensor

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

2. Loosen (2) 5mmx50mm Allen Head sensor mount screws and rotate slightly for readjustment. Retighten screws

TIRE

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

4.6 Setting and Operation of B-13 Sensor

1. Raise platform approx. 12-15” off ground and verify platform is level (tilt if necessary) 2. Loosen lock bolt and set sensor level with platform/ground (verify colored side of sensor is out) 3. Lower platform to ground. When properly set, platform should remain level for approx. 2 seconds

then tilt tip to 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.

Warning Light/Foot Control (option) MUST have all connectors inserted into platform profile after connections are made.

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4 Gate and Platform Installation

Revision 1.3 - 15 -

Lift Arm

Lift Cylinder

B-13 Sensor

Lock Tab Tilt Cylinder

12"-15"

Sensor horizontal in this position

B-13

B-15

Under torqued B-13 lock bolt may allow sensor to shift during normal gate operation.

4.7 Platform Installation

1. Support platform horizontally with forklift, overhead crane or similar equipment 2. Install platform onto lift arm using small pins 3. Tighten 4. Connect cables verifying that connectors are fully seated

Your Connectors for Warning lights, Sensors and switches from platform and gate should be marked with colored tape from the factory for easy identification and placement. Notify PALFINGER Liftgates, LLC if not.

5. Push cable and connectors into platform so that large portion of cable is clamped in cover and all connectors inside platform.

At NO time should the platform tilt tip towards ground

while lowering. Platform should ONLY tilt AFTER Lift

Arms/Nylon Rollers contact ground.

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

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

3. Fold down Lock Tab tightly onto Lift Arm

Never over torque B-13 lock bolt.

Verify colored resin side of sensor is out (facing away

from arm)

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5 Electrical Installation

Revision 1.3 - 16 -

4.8 Final Welding

Make sure to have power pack pulled out when welding the tube and hoses and cables are away from walls.

Make sure to ground to the frame and not to the platform to avoid sparking and arching on the cylinder.

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. Weld tube and mount plates (and lower gusset on 5500 lb models) with a 1/4” fillet weld 100% of the

area around mount tube and around frame on both sides of plates. The plates must have a minimum of 8” of overlap on the frame. PALFINGER Liftgates recommends adding ¼” flat bar or plate to the top of mount plates if needed to tie Liftgate mount plates to body stringer

Chassis/Trailer Frame

Mount Plate

MountTube

8" Min

100% 1/4" Fillet Weld onboth sides of Mount Plate

100% 1/4" Fillet Weld

Page 17: ILF44-55 IM v1.4 0713 · 3.1 Bed Extension & Dock Bumper Installation ... To Med. Bottle Jack Forklift or O/H Crane Hand Held Grinder Paint Gun ... 1. Read Manual completely before

5 Electrical Installation

Revision 1.3 - 17 -

4.9 Decal Placement and Inspection

For operator safety, all decals appearing in “Decal Kit” must be in a conspicuous place on control

side of liftgate. This is typically a combination of decals on the liftgate and truck or trailer body.

Please make sure to place the maximum capacity decal (C) on driver and curb side.

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

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

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

(E) 1 ATG-RESET - Circuit Breaker Protection

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

(G) 2 ATG-CTN - Caution: Always stand clear of platform area

(H) 1 ATG-CAB - Liftgate Shut-Off (Place Decal next to the On-Off Switch in the Cab)

(K) 1 ATG-WNG - Warning: Use handle to open (must be located underneath handle (main section))

(L) 1 ATG-FT- Notice for Foot Control (if applicable)

Decal - A Decal - C

Decal - D Decal - H

Decal - E

Decal - F

Decal - G

Decal - K Decal - L

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5 Electrical Installation

Revision 1.3 - 18 -

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

(B) 1 ATG-ILR-ILFS - Operational Instructions

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

(D) 2 ATG-XXXX - Max. Capacity (please check the serial number plate to fi

(E) 1 ATG-RESET - Circuit Breaker Protection

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

(G) 2 ATG-CTN - Caution: Always stand clear of platform area

(H) 1 ATG-CAB - Liftgate Shut-Off (Place Decal next to the On-Off Switch in the Cab)

(J) 1 ATG-UD - Toggle Decal

(K) 1 ATG-WNG - Warning: Use handle to open (must be located underneath handle (main section))

Figure 1: Decal Placement Guideline

Decal - A Decal - B

Decal - C

Decal G

Decal A

Decal E

Decal D

Decal F

Decal K

Decal L

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5 Electrical Installation

Revision 1.3 - 19 -

5 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, etc.

Never exceed rating of existing fuses located at the battery, control board and the pump and motor

5.1 Main Power Connections

1. Install the 2 Ga. battery cable securely from mount frame to battery. 2. Secure the cable every 12 inches. 3. Heat shrink lug connection to cable. 4. Assure all connections are tight and securely fastened.

Circuit breaker MUST be fastened securely

Gro

und C

able

Ground

(Third Battery Shownfor 6600 # or heavy applications Only)

CircuitBreaker

+

+

-

-

Liftgate Mount Frame

Control Power 4-Wire Cable

Main Batteries

2 G

a. Lift

gate

Pow

er C

able

Ground

MainDisconnect

(ifapplicable)

Truck Application-Always wire to truck battery

+-

Trailer Application-wire to aux. battery

+ -To Ignition Switch

Ground

Aux. Batteries (if applicable)

BatteryIsolator

(if applicable)

+ -

Wires marked#2 ; #4 go to hot,#1 and gr/ylgo to ground

CircuitBreaker

In-LineFuse on #2 and #27

FOLLOW DOTTED LINE IF ISOLATOR OR AUXILLIARY BATTERIES INSTALLED!

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5 Electrical Installation

Revision 1.3 - 20 -

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.

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

150 AMP Resetable Breaker

RES

ET

Connect 4 Wire Harness directly to Truck Battery

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 extend out side the van body when open.

2. Lead the 4-wire cab switch cable together with the battery cable and the 4 wire harness 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 the cab switch cable only into the cab

5.2 On-off switch installation (Truck / In-Cab)

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

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5 Electrical Installation

Revision 1.3 - 21 -

Do Not use In-Cab Switch for Trailer Applications. Your Liftgate should be outfitted with a Trailer Cut Off Switch and Wiring in Control Box from the factory. If not, refer to “Cut Off Switch for Trailer Application” 5.3. 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

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 Shut 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 From Batteries - RED 4 = Control Power To Liftgate - BLUE

1. Install the supplied breaker to the positive terminal of the battery using brass lug. Install the 2 ga. cable from the power pack to circuit breaker.

2. Install the 4 wire harness for the control power to the batteries. Attach 2 and 4 to positive with an in-line 20 amp fuse at the battery, wire 1 and green and yellow to negative on battery.

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5 Electrical Installation

Revision 1.3 - 22 -

5.3 On-off Switch Trailer application

On a trailer installation the control port J11 has to be connected with a on off toggle switch connecting 2 and

4 on port J11 together.

Unplug exsiting J11 connector from board

Install 2 Position Toggle Switch in Control Box Face

Run leads from Toggle Switch to #2 & #4 on Circuit Board

Use Tie Straps to hold unused J11 Connector in safe location

On-Off-Switch

The Circuit Board is located behind the rubber cover on the curb side of the 7” x 7” mount tube.

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5 Electrical Installation

Revision 1.3 - 23 -

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

5.4 Remote Hand Control Installation

Hand Controls are NOT weatherproof and are 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

3

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 – 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

Existing Wire on Gate:

1. Find hot wire & touch hot wire to other wires.

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5 Electrical Installation

Revision 1.3 - 24 -

2. Note function and match to above. Optional Plug and Socket application

2 Button Hand Control

#4

#2

#1

Female Receptical (Looking at Front)

#3

Green/Yellow

Figure 5.1: Plug& Socket wiring for Hand Control

5.5 Foot Control installation

After installing the platform connect the wiring harness from the platform to the connections at the liftarm. Each foot switch has a hot (wire #4) on plug J3. Switch (1) connects in addition to port (5) on J3, switch (2) connects to port (6) on J3. Make sure that connections are wire tied together and pushed inside the platform.

DOWN: Step on switch 1 and hold – wait between one and three seconds before you step on switch 2.

UP: Step on switch 2 and hold – wait between one and three seconds before you step on switch 1. The platform will tilt up to preset position before raising.

IF BOTH SWITCHES ARE NOT ACTIVATED BETWEEN ONE TO THREE SECONDS, START OVER.

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5 Electrical Installation

Revision 1.3 - 25 -

5.6 Wiring Diagram

150

# 2

BLA

CK

# 4

BLA

CK

# 1

BLA

CK

GR

EE

N / Y

ELLO

W

(+)

(-)

ILF

44/5

5 K

PLU

S

CIR

CU

IT B

OA

RD

OP

EN

WIR

ELE

SS

HA

ND

CO

NT

RO

L

OP

TIO

NA

L

Legend

:

gn : g

reen

bl : b

lue

br : b

row

nw

t : white

ye : ye

llow

sw / b

k : bla

ckgy : g

reen-ye

llow

LI : L

ift Up

LO

: Low

er D

ow

nO

P : O

pen G

ate

CL : C

lose

Gate

* Good voltage is the m

ost important first step

in troubleshooting the litgate.* Test voltage at the J11connection between wire 4 and ground (m

in. 10 V ).* W

hen testing for electricity on the individual solenoid plug at the cylinder, always test voltage between the two prongs on the plug itself.(m

in. 7 V)* After troubleshooting, carefully close the rubber cap and secure it with the plastic strap.

CLO

SE

LO

WE

R

LIF

T

HA

CK

BA

RT

H

* When te

sting th

e vo

ltage o

n d

iffere

nt

loca

tions, a

lways g

round o

n p

lug J1

.

Tilt - U

p b

ypass -- J11

#4 m

in. 8

.5 V

Figure 5.2: Electrical scematic

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5 Electrical Installation

Revision 1.3 - 26 -

B13 L

IFT A

RM

B15 P

LAT

FO

RM

FO

OT

CO

NT

RO

L

WA

RN

ING

LIG

HT

S

CA

B C

UT O

FF

SW

ITC

HC

ON

TR

OL

BO

X

HA

ND

RE

MO

TE

PO

WE

R P

AC

K

GR

OU

ND

for P

C B

OA

RD

(gre

en/ye

llow

and b

lack #

1)

CIR

CU

IT B

OA

RD

K+

PO

SIT

IVE

for P

C B

OA

RD

(bla

ck #2 to

2

and b

lack #

4 to

27)

CY

LIN

DE

RS

LIF

T 1

5 (2

ea)

TILT

14 (2

ea)

AU

X p

ort

Figure 5.3: Electrical wieing overwiev

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6 Lubrication and Final InspectionL

Revision 1.3 - 27 -

6 Lubrication and Final Inspection

1. Open platform and lift gate to bed level

2. Remove red caps, apply grease until grease begins to flow from bushing ends (12 points)

3. Lower platform to ground and repeat

4. Cycle platform up and down, fold in and out several times and grease again (Fig. 6.1)

5. Wipe excess grease from joints and replace ALL red caps

6. Check ALL pin bolts for proper torque of 14 ft-lbs

7. Paint all welded areas and area that have been scratched during installation

Note:- Do not paint chrome hydraulic shafts

8. Remove any overspray from cylinder shafts

9. Check for any wires or hoses that may rub during operation.

10. Re-route and/or tie up wires and hoses as necessary

11. Lower platform completely to ground to check oil

12. Slide out pump/motor on curb side and check oil level

13. Check Plugs on PC Board. Push tight and reinstall clamp on cover

14. Install all operation and safety decals (Error! Reference source not found.)

TIRE TIRE

1

2

3

4

5

6

Figure 6.1: Lubrication Points (opposite direction on curb side )

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6 Lubrication and Final InspectionL

Revision 1.3 - 28 -

6.1 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

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7 Check Off Sheet

Revision 1.3 - 29 -

7 Check Off Sheet

SECURED 2. No Rubbing On Platform 6. Platform hits rear sill even

3. Up-Down Clear at the same time

4. Storing Platform Clear 7. Titl cylinder clevis

adjusted properly

HYD. OIL 1. None At Hoses 8. No Paint on cylinder On Auto Tilt KnuckleLEAKS 2. None Power Pack shafts

3. Cylinders

FINAL 1. Platform Touches Ground

WELDS 1. Full Welds Mount Plates INSPECTION 2. Lights Working On Chassis

2. Ground Off / Clean 3. Lic. Plate Bolts & Lights

3. Frame Capped Off 4. Decals Installed

5. Rubber & Plastic Caps

In Place

PUMP 1. Check Fluid With Platform On Ground 6. Gate Painted Completely

& MOTOR 2. Connections Tight With Heat Shrink 7. Body Clean Around Gate

3. Power Cable Tight 8. Pin Greased - 12 Places

4. Ground Cable Tight 9. Cylinders Clean

5. Breather Installed

6. Cables Tied Off OPTIONS 1. All Options On Gate

7. Fuses Tight 2. Circuit Breaker Tight

8. Clamp on rubber cover & Decal In Place

3. Cart Stops Working

PINS 1. Grease Zerks In Place

2. Red Grease Caps On Zerks CHECKED BY

3. Bolts Tight On Pins

4. Ground Rollers On DATE

(only 44 and 55)

Note:

This must be filled out and kept for your records . A copy of this sheet must be presented

to PALFINGER Liftgates for any warranty compensation