Palfinger ILU Under Slider 50, ILU Under Slider 40 Owner's Manual

ILU

OWNER’S MANUAL

ECN-M1143 Rev. 1.5, Date 12-19-17 Part #90-1313-100

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

Tel [phone] Fax [phone]

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

Tel [phone] Fax [phone]

Visit our website at www.palfinger.com for up to date information and notifications

If you received this product with damaged or missing parts,

Please contact PALFINGER Liftgates at (888)-774-5844

I

Table of Content

1. Important Notes ...................................................................................................... 1

1.1 Attention ..................................................................................................... 1

1.2 Important Notes .......................................................................................... 1

1.3 General Information .................................................................................... 2

2. Safety Information .................................................................................................. 4

3. Basic Parts in Detail ............................................................................................... 6

3.1 General View of Liftgate ............................................................................. 6

3.2 Maximum Load and Placing of Load on Platform ........................................ 7

4. Operation of Liftgate .............................................................................................. 8

4.1 Operating the ILU by Control Box ............................................................... 8

4.1.1 General Instructions for the ILU Unfolding Process ....................... 8

4.2 Operation by Hand Held Remote Control.................................................. 10

4.3 Operation by Foot Control ........................................................................ 11

4.4 Operation by Wireless hand Held Remote (optional) ................................ 11

5. Preventive Maintenance and Quick Check ......................................................... 13

5.1 Maintenance and Care ............................................................................. 13

5.2 Cross Test on Single Pole Plug Charge System ....................................... 14

5.3 Lubrication ................................................................................................ 15

5.3.1 Lubrication Plan .......................................................................... 15

5.3.2 Checking and Changing the Oil ................................................... 17

5.3.3 Recommended Hydraulic Fluids ................................................. 17

5.4 Decal Placement and Inspection .............................................................. 18

5.5 Quick Check List ....................................................................................... 20

6. Troubleshooting ................................................................ ................................... 21

6.1 Basic Function Check ............................................................................... 21

6.1.1 LIFTGATE is competely DEAD (No Clicking or Movement at all) 21

6.1.2 ON-OFF switch on, but all functions are dead ............................. 23

6.1.3 Warning Lights on, after switch is turned off ................................ 24

6.1.4 Platform tilts down before it reaches the ground.......................... 24

6.2 Electrical and Hydraulic Schematic ........................................................... 25

6.2.1 Wiring Diagram ........................................................................... 25

6.2.2 Electrical Schematic .................................................................... 27

6.2.3 Connector Overview ................................................................... 28

6.2.4 Hydraulic Schematic ................................................................... 30

6.3 Functional Description of Hydraulics when Operating ............................... 31

6.3.1 Slide Out Function ...................................................................... 31

Revision 1.5 II

6.3.2 Lower Down and Auto Tilt Function............................................. 31

6.3.3 Level Out Activity ........................................................................ 31

6.3.4 Lift Up Function ........................................................................... 32

6.3.5 Slide In Function ......................................................................... 32

7. Needed Information for Ordering Spare Parts and Repairs .............................. 33

7.1 Ordering Spare Parts ................................................................................ 33

7.2 Repairs ..................................................................................................... 33

8. Warranty ............................................................................................................... 34

9. Contact Address .................................................................................................. 35

ILU 40/50 Owner’s Manual

Revision 1.5 1

1. Important Notes

1.1 Attention

Before starting any operations of the liftgate, please read and understand this OWNER’S MANUAL. Its
intention is to act as a guide for the operation personal as well as to give help with preventive maintenance but
does not take place of unauthorized usage or repair by unqualified personnel.
Please contact your nearest PALFINGER Liftgates distributor or PALFINGER Liftgates in California or New
Jersey for assistance if you have questions regarding installation, operation or maintenance.

This owner’s manual applies to the following models: ILU Under Slider 40, 50

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.

1.2 Important Notes

This PALFINGER Liftgate is an electro-hydraulically driven lift gate, designed to be stored underneath the
truck or trailer for ultimate dock loading as well as offering up to seven foot platform.
The Hydraulic Power Unit (HPU) is easily accessible for service and exchange. The whole assembly slides out
and can be serviced at that point. To exchange the Hydraulic Power Unit (HPU), two hoses and the battery
cables need to be disconnected.

The platform folded in half is supported by two arms, linked with a torsion tube. The platform in a stored
position acts as the under ride guard. Lifting actions are carried out by hydraulic cylinders mounted on the lift
arms.

Two hydraulic tilt cylinders, one on each side of the lift arms are controlling the platform’s tilting action. This

enables the platform to maintain its position throughout the lift mode, regardless of the terrain.
The hydraulic cylinders are equipped with solenoid operated valves located at the port of each cylinder which
prevents the platform from lowering accidently unless the operator is activating the controls. This system also
enables you to store the lift gate without a separate platform latch.

The piston rods are treated against corrosion and also protected with plastic or rubber boots to protect from
road gravel and dirt. The HPU is equipped with a built-in pressure relief valve, which prevents overloading
when lifting or tilting up.

The valves do not prevent overloading of the platform when lowering or tilting down.

ILU 40/50 Owner’s Manual

Revision 1.5 2

The electric supply is taken from the vehicle battery. If the vehicle battery is not sufficient or not existing (like
on trailer units), an auxiliary battery kit needs to be installed. The electric control power is protected via a 20
Amp fuse and an on-off switch. The switch has L.E.D. lights indicating when the control power is on. (Trailer
applications have an on-off switch located in the lockable control box).
The liftgate is operated from an outside control box which is located on the curbside underneath the body. A
standard 2-button hand held remote control is also supplied with the lift. Foot controls are standard, which
enables the operator to handle the cargo and operate the lift by foot. A variety of different products can be
purchased with the PALFINGER Liftgate as well.

1.3 General Information

REMEMBER!

It is the fleet manager’s responsibility to educate the operator on the liftgate and its intended use. The

operator’s attention should be drawn to the permitted load limits and an understanding of the operation to

ensure the safety throughout the operation.

ONE-MAN OPERATION!

Never let an “outsider” operate the liftgate while you are handling the cargo.
A “misunderstanding” can result in serious personal injury.

In the interest of safety it is important that all operating personnel properly understand the functions of
the lift gate, possible hazards, dangers, the load limits and load positioning for that specific unit.

IMPORTANT NOTICE!

Before the operator uses the lift gate, they should be thoroughly familiar with the lift’s functions and
usage according to the following:

1. Improper operation of this lift can result in serious personal injury. Do not operate unless you have
been properly instructed, have read and are familiar with the operation instructions. If you do not have
a copy of the instructions please obtain them from your employer, distributor or lessor, as appropriate,
before you attempt to operate the lift.

2. Be certain the vehicle is properly and securely stopped before using the lift.

ILU 40/50 Owner’s Manual

Revision 1.5 3

3. Always inspect this lift for maintenance or damage before using it. If there are signs of improper
maintenance, damage to vital parts or slippery platform surface, do not use the lift. Do not attempt your
own repairs unless you are specifically trained.

4. Do not overload. See the Rating Label on the unit for the rated load. Remember that this limit applies
to both raising and lowering operations.

5. Each load should be placed in a stable position as near as possible to the body of the truck/trailer.

6. Never stand in, move through or allow anyone else to stand in or move through the area in which the
lift operates, including that area in which a load might fall.

7. This is not a passenger lift. Do not ride the lift with unstable loads or in such a manner that a failure
would endanger you. The lift is not equipped with a back-up system to prevent falling cargo in the
event of a failure.

The maximum loads must be observed and followed!

IMPROPER USE

It is not permitted to use the tail lift:

 As an elevating work platform
 To push loads
 To carry people (Only the operator may travel on the platform)
 To clear snow

Please read through the operational and technical description of this PALFINGER Liftgate.

Thank you for choosing PALFINGER Liftgates

ILU 40/50 Owner’s Manual

Revision 1.5 4

2. Safety Information

This manual follows the Guidelines set forth in “ANSI Z535.4-2007” for alerting you to possible hazards and
their potential severity.

! DANGER indicates an imminently hazardous situation which, if not avoided, will result in death or serious
injury.

! WARNING indicates potentially hazardous situation which, if not avoided, could result in death or serious
injury.

! CAUTION indicates a potentially hazardous situation which, if not avoided, may result in minor or moderate
injury.

CAUTION without the safety alert symbol is used to address practices not related to personal injury.
(In this manual we use it to alert you to potentially hazardous situation which, if not avoided, may result in
property damage.)

NOTICE without the safety alert symbol is used to address practices not related to personal injury. (In this
manual we use it to alert you to special instructions, steps, or procedures.)

ILU 40/50 Owner’s Manual

Revision 1.5 5

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. We have
designed this manual to illustrate the steps needed for the basic operation of this ILUK 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 ILU series liftgate only which is designed for
different capacities. You have different options to determine the type of your Liftgate:

1) Refer to the serial number tag on the Liftgate.

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 [phone], or on the internet- www.PALFINGER.com

If you are facing any problems or are in need of repair, contact PALFINGER Liftgates for information regarding
experienced and trained Authorized Service Center in your area.

Replacement manuals are available, just call us & order your manuals for FREE.

ILU 40/50 Owner’s Manual

Revision 1.5 6

Mount Frame

Tilt Cylinder

Lift Arm

Lift Cylinder

Center of Gravity of

maximum Load

Warning Lights

Cart Stops
Platform

Push-Pull Cylinders

2 Button Hand Control

Control
Box

Circuit Board

(behind cover)

Liftarm Sensor

B13

Platform

Sensor B15

Foot Controls

Slider Rails

3. Basic Parts in Detail

3.1 General View of Liftgate

Figure 1: ILU Under Slider

ILU 40/50 Owner’s Manual

Revision 1.5 7

A = Distance from Truck Body to the Center
Point of Load on the Platform

Truck or Trailer
Body

Q = Weight

Load diagram

10

20

30

40

50

60

70

80

90

100

0 12 24 36 48 60 72 84

distance from body (inch)

capacity (%)

3.2 Maximum Load and Placing of Load on Platform

Every PALFINGER Liftgates is rated up to a maximum load. The point of maximum load is rated at a defined
distance. The center point of maximum load is at 24” for all ILU liftgates from start of Truck or Trailer Body, as
shown in Figure 2.

Figure 2: Center Point of Load

By increasing this distance the maximum load of the lift gate is decreasing.

An overview about the rating depending, on the distance from the end of the platform is shown in the following
load diagram.

Figure 3: Load Diagram (ILU 40, 50)

Capacity:

100% at 24”
80% at 36”

60% at 48”
45% at 60”

ILU 40/50 Owner’s Manual

Revision 1.5 8

4. Operation of Liftgate

Before use: Turn Control power to “ON”. All lift gate functions can be controlled with the 3-button control

box, which is mounted on the curb side of the truck or trailer.

NOTE: Never slide platform in or out with load on the platform.

4.1 Operating the ILU by Control Box

4.1.1 General Instructions for the ILU Unfolding Process

1. Turn on the liftgate by rotating the ON-button

on the right side of your Control Box.
Warning-Lights will start flashing.

2. Lowering down
By rotating the lower button down you will lower
the lift gate from its storage position

3. Slide out the liftgate
Rotate the center button down to slide out the gate
completely until you hit the stops.

4. Unfold the platform manually by using the nylon strap

5. Check out auto tilt function
Rotate the lower button down to lower the platform
to the ground. If you continue holding the switch, the
tip of the platform will automatically tilt down.

6. Auto tilt up to level and raising
To raise platform to the body floor, rotate the
lower switch up.

ILU 40/50 Owner’s Manual

Revision 1.5 9

7. Fold the platform manually
Lower down the platform to the ground. To fold the
platform, flip the tip section onto the main section.

8. Sliding in
Rotate the center button up to slide the lift gate
underneath your vehicle till the gate is in its final
position and does not more further back.

9. Raising up
By rotating the lower button up you will raise
the lift gate up to its storage position.

10. Turn off all functions by rotating the right button
into the OFF position. The flashing lights turns off.