ILUK Owners Manual - 06-2018 PDF

OWNER’S MANUAL
ILUK 33, 3300 lbs. Capacity

06/18
ILUK 33/44/55/60 Owner’s Manual
ILUK 33/44/55/60 Owner‘s Manual

Document Part Number: 90-0513-100 / 13-691_90-00_01-00
ECN-M01205, Rev. 1.5, 06-04-18
Copyright © 2018 Palfinger Liftgates LLC.
All rights reserved.
Information in this document is subject to change without notice.

Visit www.palfinger.com for up to date information and notifications.
If you received this product with damaged or missing parts,

contact Palfinger Liftgates at (888)-774-5844
Parts Order
liftgateparts@palfinger.com
15939 Piuma Ave.

Cerritos, CA 90703
Tel (888)-774-5844
Fax (562)-924-8318
572 Whitehead Road.

Trenton, NJ 08619
Tel (609)-587-4200
Fax (609)-587-4201
Rev.1.5 2
Table of Contents
1 Manual Updates ........................................................................................................................ 5
2 Important Notes ........................................................................................................................ 6
2.1 Attention ....................................................................................................................... 6
2.2 Important Notes ............................................................................................................ 6
2.3 General Information ...................................................................................................... 7
3 Safety Information .................................................................................................................... 9
4 General View of Liftgate ........................................................................................................... 11
4.1 ILUK 33/44/55/60 General Overview for Trailers ........................................................... 11
4.2 ILUK 33/44/55/60 General Overview for Trucks ............................................................ 12
5 Maximum Load and Placing of Load on Platform .................................................................. 13
6 Operation of Liftgate ................................................................................................................ 14
6.1 Operation Control Box................................................................................................... 14
6.2 Hand Held Remote Control ........................................................................................... 19
6.3 Wireless Hand Held Remote (Optional) ........................................................................ 19
6.4 Aluminum Platform Cart Stop Operation (Optional) ....................................................... 20
6.5 Foot Controls Operation (Optional) ............................................................................... 21
7 Preventive Maintenance and Quick Check ............................................................................. 22
7.1 Maintenance and Care .................................................................................................. 22
7.2 Lubrication .................................................................................................................... 23
7.3 Checking and Changing the Oil..................................................................................... 24
7.4 Decal Placement and Inspection ................................................................................... 25
7.5 Quick Check List ........................................................................................................... 27
8 Troubleshooting ....................................................................................................................... 28
8.1.1 Liftgate will not power on. ................................................................................ 28
8.1.2 ON-OFF Switch is On, But All Functions are Dead .......................................... 31
8.1.3 Warning Lights ON, after ON-OFF Switch is Turned OFF ............................... 31
8.1.4 Platform Tilts Down Before it Reaches The Ground ........................................ 31
8.2 Electrical Wiring – Batteries – Truck/Trailer................................................................... 32
8.3 Electrical System Codes ............................................................................................... 33
8.4 Connector Overview ..................................................................................................... 34
8.5 Cross Test on Single Pole Plug Charge System ........................................................... 35
8.6 Electrical Schematic ...................................................................................................... 36
8.7 Hydraulic Schematics.................................................................................................... 37
Rev.1.5 3
8.8 Functional Description of Hydrualics When Operating .................................................. 38

8.8.1 Slide Out Function ........................................................................................... 38
8.8.2 Lower Down and Auto Tilt Function ................................................................. 38
8.8.3 Level Out Activity............................................................................................. 38
8.8.4 Lift Up Function ............................................................................................... 39
8.8.5 Slide In Function.............................................................................................. 39
8.9 ILUK Push Pull Valving ................................................................................................. 40
9 Needed Information for Ordering Spare Parts and Repairs ................................................... 42
9.1 Ordering Spare Parts .................................................................................................... 42
9.2 Repairs ......................................................................................................................... 42
10 Warranty .................................................................................................................................... 42
11 Contact Address ....................................................................................................................... 43
Company Information:
Company Name:
Advisor Name:
Vehicle Year Make & Model:
Liftgate Information:
Liftgate Serial Number:
Liftgate Model Number:
Date of Purchase:
Date of Installation:
Thank you for choosing Palfinger Liftgates.
Rev.1.5 4
1 Manual Updates
Revision Description
v1.5  Reformatted manual to standard format.
 Revised Liftgate Operiational Instructions.
 Updated Electrical Schematic.
Rev.1.5 5
2 Important Notes
2.1 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: ILUK Under Slider 33, 44, 55 & 60
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.
2.2 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.
Rev.1.5 6
The valves do not prevent overloading of the platform when lowering or tilting down.
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
application 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 (except
for the ILUK 33), 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.
2.3 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.
Rev.1.5 7
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.
Rev.1.5 8
3 Safety Information
This manual follows the Guidelines set forth in ANSI X535.4-2007 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.)
Rev.1.5 9
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 an
PALFINGER Liftgates Authorized Service Center.
This Manual has been designed for use in conjunction with the ILUK 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 (562) 924-8318, 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 to download at www.palfinger.com.
Rev.1.5 10
4 General View of Liftgate
4.1 ILUK 33/44/55/60 General Overview for Trailers
Rapid Mount
Bolt-On (RMB) Tray
(3",5",8" or 10"H)
Push Pull
Cylinders
Slider Bracket
Rapid Mount Rails
Bolt-On (RMB) Tray
(3",5",8" or 10"H)
Push/Pull
Cylinders
w/Tray
Slide
Rail
Stops Wire
Lift
Management
Cylinders
Bar w/Rings
Control
Platform Box
Platform Control
Bumpers Board
(PCB)
Tilt Hydraulic
Cylinders Power
Unit
Liftarms
Foot Controls
Warning
Lights
Rev.1.5 11
4.2 ILUK 33/44/55/60 General Overview for Trucks
Mounting Slider
Brackets Rails
w/Hardware Push Pull
Cylinders
Bracket
Slide
Rail
Stops
Wire
Management
Slide Bar w/Rings
Rail Control Box
Stops w/Mount Brackets
Push/Pull
Cylinders
w/Tray
Tilt
Cylinders
Mount
Lift Plates
Cylinders Control
Board
(PCB)
Platform
Tilt Hydraulic
Cylinders Power
Unit
Liftarms
Foot Controls
Warning
Lights
Rev.1.5 12
.
5 Maximum Load and Placing of Load on Platform

Every Palfinger Liftgate 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” from the rear of the bed extension out to the platform.
24"
Load
By increasing this distance the maximum load of the liftgate is decreasing.

An overview about the rating depending, on the distance from the end of the platform is shown in the
following load diagram.
100
Capacity:
90
100% at 24”
80
80% at 36”
70 60% at 48”
45% at 60”
60
Capacity (%)
33% at 72”
50
40
30
20
10
24 36 48 60 72 84
Distance From Body (inches)
Rev.1.5 13
6 Operation of Liftgate
6.1 Operation with Control Box
Always stand clear of platform area when operating the liftgate.

To Open Liftgate
1. Power on the liftgate by switching the ON/OFF switch ON. ON/OFF switch location for a truck is
located in the cab, for a trailer it will be located on the control box.
Up
Tilt ILUK / ILU
• To operate this liftgate read and understand the
operating decals and manuals.
Down • Make certain the platform is clear before
operating the lift.
• Liftgate shut-off switch must be turned off when
liftgate is not in use.
• Keep platform in horizontal position when
In loading and unloading.
• Do not overload, refer to capacity decals.
Slide • Lower platform
Out
Loading Position: • Slide out liftgate
Storage Position:
• Unfold platform
• In down position fold up
platform tip
On-Off
Up
• Slide in liftgate
• Raise platform
24" Switch
Lift Max Capacity
on Platform
Load
Down Platform
For questions regarding operation call (888) 774-5844
ON/OFF Switch ON/OFF Switch

Location for Trucks Location for Trailers
2. Use the Lift Down switch lower the platform approximate 5” from the platform upstop.
Floor
Sill
Tilt
Crossmembers
Longsill
Wooden Spacer(s)
Chassis
Platform
Slide
Upstop
Lift
3. Use the Slide Out switch to slide out the entire liftgate until the mount frame makes contact with the
slide rail stop.
Floor
Sill
Tilt
Crossmembers
Longsill
Wooden Spacer(s)
Chassis
Slide
Lift
Rev.1.5 14
4. Use the strap handle on the tip to manually open the platform tip.
Strap
Handle
Floor
Sill
Crossmembers
Longsill
Wooden Spacer(s)
Chassis
5. Use the Lift Up switch to raise the platform up to bed level until the liftarms are in contact with the
liftarm upstops.
Floor
Sill
Crossmembers
Longsill
Wooden Spacer(s)
Chassis Tilt
Slide
Lift
6. Center the load on the platform 24“ away from the rear of the vehicle sill.
24"
Load
Floor
Sill
Crossmembers
Longsill
Wooden Spacer(s)
Chassis
Rev.1.5 15
7. Use the Lift Down switch to lower the platform until the ground rollers on the platform reach the
ground. NOTE: Maintaining the Lift Down switch down will cause the platform to tilt down.
Floor
Sill
Tilt
Crossmembers
Longsill
Slide
Wooden Spacer(s)
Chassis
Lift
Load
Rev.1.5 16
To Store Liftgate
1. Use the Lift Up switch to raise the platform parallel to the ground.
Tilt
Floor
Sill
Crossmembers
Longsill
Wooden Spacer(s)
Chassis
Slide
Lift
2. Use the Lift Up switch to raise the platform approximately 10“ from the ground. Fold the tip manaully
using the strap and secure the tip to the main with same strap.
Floor
Sill
Crossmembers
Longsill
Wooden Spacer(s)
Chassis
10"
3. Use the Slide In switch to store the gate.

Floor
Crossmembers
Sill
Tilt
Longsill
Wooden Spacer(s)
Chassis
Slide
Lift
Rev.1.5 17
4. Use the Lift Up switch to raise the platform up to the platform bumpers
Floor
Sill
Tilt
Crossmembers
Longsill
Wooden Spacer(s)
Chassis
Slide
Lift
5. Turn liftgate OFF.
Up
Tilt ILUK / ILU
operating the lift.
Out
Storage Position:
• Unfold platform
platform tip
On-Off
Up
• Raise platform
24" Switch
Lift Max Capacity
on Platform
Load
Down Platform

Rev.1.5 18
6.2 Hand Held Remote Control
Reminder: Do not store remote inside refrigerated vehicles. Control will be damaged.
1. Lowering Down
Press and hold the black button to lower platform.
2. Lifting Up
Press and hold the white button to raise platform.
3. Tilt Down (at Ground Level)
Press and hold the button until the platform starts tilting down.
4. Tilt Up (at Ground Level)
Press and hold the button until the platform starts tilting up.
Lift UP White Button

Tilt Up (at ground level)
Lift DOWN Black Button

Tilt Down (at ground level)
6.3 Wireless Hand Held Remote (Optional)

1. Read the wireless remote owner’s manual before operating the liftgate.
2. Power the remote by using the ON/OFF switch on the rear of the control.
3. Each function has a separate button. Functions are displayed below.
4. After finishing using the gate, switch the power OFF on the remote.
5. Maintain the remote in the cab of the vehicle.
Slide Out (A) Slide In (B)

Slide platform Slide platform in to
out from stored position
stored position
Tilt Down
Tilt platform down
Down
Lower platform
Up
Raise platform
Tilt Up
Tilt platform up
Rev.1.5 19
6.4 Aluminum Platform Cart Stop Operation (Optional)
1. Push the cart stop latch out toward the curb side. The cart stop will spring open automatically
once the latch has been moved from its original position.
2. To close the cart stops, push the cart stop latch inward towards the street side. After the latch is
in place close each cart stop by pushing each stop down.
Cart Stop
(Closed)
Latch
Platform
Tip
Cart
Stops
(Closed Position)
Cart Stop
(Open)
Latch
Platform
Tip
Cart
Stops
(Open Position)
Cart Stop
(Open)
Latch
Platform
Tip
Cart
Stops
(Open Position)
Note: One latch is used for both cart stops.
Rev.1.5 20
6.5 Foot Controls Operation (Optional)

Lower Platform:
Step on the front foot control and hold, wait three seconds before stepping on the rear foot control.
For auto tilt, stay on the switches until the platform starts tilting.
Raise Platform:
Step on the rear foot control and hold, wait three seconds before stepping on the front foot control.
The platform will tilt up to preset postion before raising.
IF THE PLATFORM IS NOT RESPONDING TO THE CONTROLS WITHIN THREE SECONDS, REPEAT
STEPS ABOVE.
Lower Platform
Front Front Foot RearFoot

Control Control
Rear Raise Platform
Front Foot RearFoot

Control Control
Rev.1.5 21
7 Preventive Maintenance and Quick Check

The ILUK needs preventive maintenance to perform at its fullest capability. Lubricate and inspect regularly.
Also, check that all details are not damaged: Hoses, cables, controls, etc.
REPAIR OR REPLACE FAULTY PARTS IMMEDIATELY
7.1 Maintenance and Care

The following inspection and maintenance should be performed at the recommended intervals depending
on operation and amount of cycles or at the time when the unit shows any signs of damage or abuse.
Remember that the secret to a long life of your PALFINGER Liftgates is to maintain it through preventive
care.
* Recommended bases for Depending
Daily Monthly Quarterly
inspection and maintenance on use
Cleaning 
General lubrication of pins and

bushings
General lubrication of Slider Rails with
WD-40 and Push-Pull Cylinder zerks 
with grease
Oil level inspection 
Oil change 
Check hydraulic hoses and pipes for

leaks
Check controls and connections 
Check platform retention bar 
Check pins and pin retaining bolts 
Check batteries and connections 
Check warning labels and other safety
equipment for effectiveness and 
visibility
Visual check for loose or missing parts

and un-usual noise during operation
Check lock bolts and pins for tightness 
Check complete function of gate 
Check mounting brackets of lift gate to

frame for cracks or damage visually
Do not cover up any accidents or damage; it can be dangerous for you and your co-workers.
Rev.1.5 22
7.2 Lubrication
Properly lubricated, the ILUK PALFINGER Liftgate will ensure longevity. Therefore, lubricate the lift at the
same time as the truck/trailer. Grease more frequently if the liftgate is heavily used. The liftgate should be
greased every 500 cycles (depending on use – estimated every 3 month).
Check the oil level in the tank. The level should be between the two marks 5 and 7 when the platform is
tilted down at ground level in stored position. Use a good quality of hydraulic fluid, ISO 32. Change oil at
least once a year, preferably in the fall before the weather gets cold. The operation of the lift gate will
accumulate condensation and some dirt which can interfere with the lift gate functions.
4 zerks:
- 2 Lift Cylinder -Mount Plates
- 1 Lift arm Slide Pad
- 1 Tilt Cylinder
3 zerks: Oil reservoir

- 1 Tilt Cylinder inside main tube.
- 1 Liftarm Pull out tray to
- 1 Lift Cylinder check and refill oil.
4 zerks:
- 2 Lift Cylinder
- 1 Lift arm
- 1 Tilt Cylinder
3 zerks:
- 1 Tilt Cylinder
- 1 Liftarm
- 1 Lift Cylinder
-Platform Hinges
-Cart Stops (If, installed)
Grease: Location of Grease Zerks (7 on each side, 14 total).
Hydraulic Oil: Oil level in the power pack tank (see marking inside of power pack reservoir).
Penetrating Oil: Platform hinges, Slide Rails and optional Cart Stops.
Rev.1.5 23
7.3 Checking and Changing the Oil
To check fluid:
1. To begin, lower gate to ground and tilt platform down.
2. Remove the cover from the Hydraulic Power Unit enclosure. The cover is hinged and opens to right.
3. The level of the oil should be 2“ from the top of the oil reservoir when the platform is tilted down at
ground level. If fluid is required, use a recommended fluid from the table below.
Remove Pull Out

Metal Brace Hardware Pump & Motor
Pump and Motor Located Inside Mount Frame on the Right Side.
To change fluid:
1. Unscrew the Oil Drain Bolt and let the fluid drain out of the reservoir into an approved cointainer.
When reservoir is empty fill the reservoir up 2“ from the top of the reservoir. Change oil at least once
a year, preferable in the fall before the weather gets cold.
2. Place the cover back on to the Hydraulic Power Unit enclosure.
Oil Filler 2"
Oil Drain Bolt

When changing or adding fluids, it is highly recommended to use alternatives fluid brands and types listed
below:
Alternative Fluids
Temperature Range Fluid Brand
EXXON UNIVIS J26
30° to 150° F MOBIL DTE 13M
CHEVRON AW MV32
ROSEMEAD MV 150 (32)
HYDREX MV ARCTIC 15
-50° to 150° F MOBILE DTE 11
SHELL AERO FLUID 4/41
SHELL TELLUS 15
Extreme Cold Temperature MIL H5606 (Military Spec.)
Rev.1.5 24
7.4 Decal Placement and Inspection
For operator’s safety, all decals appearing in “Decal Kit” must be placed visibly on the control
side of liftgate to be read by operator. This is typically a combination of decals on the liftgate and
truck/trailer body.
Important: Never remove or paint over any decal. If any decals below require replacement contact
Palfinger Liftgates for replacements.
Decal Kit
Decal Qty. Part No. Description
A 1 ATG-URGWA Urgent Warning: Elevating Gate Instructions
B 1 ATG-ILUK Operating Instructions
C 1 ATG-BKR Circuit Breaker Reset (must be located at the
circuit breaker)
D 2 ATG-XXXX Capacity (check the serial number plate to find out
the gates specific capacity).
E 1 ATG-RESET Circuit Breaker Protection
F 2 ATG-WLH Warning: Liftgate Can Crush

G 2 ATG-PLAT Warning: Always Stand Clear of Platform Area
H 1 ATG-CAB Liftgate Shut-Off (Place Decal next to the On-Off
Switch in the Cab)
I 1 ATG-WNG Warning: Use handle to open (must be located
underneath handle (main section))
J 1 ATG-FC Foot Controls (Optional)
K 1 2032626 Palfinger Logo (Trailer Only)
It is the installer’s responsibility to determine that the vehicle meets DOT and federal lighting
regulations. Keep in mind that there are different requirements depending on the classification of
the vehicle. This document is not intended to replace published agency regulations, and it is
strongly recommended that the installer references the Code of Federal Regulations (CFR) which
can be viewed at http://www.ecfr.gov
Rev.1.5 25
Up ELECTRICAL SYSTEM
BEFORE OPERATING LIFT, BE SURE YOU UNDERSTAND: Tilt ILUK / ILU PROTECTED BY
RESETTABLE CIRCUIT
• To operate this liftgate read and understand the BREAKER
1. Improper operation of this lift gate can result in serious personal injury. Do operating decals and manuals.
not operate unless you have been properly instructed, have read, and are Down
familiar with, the operating instructions. If you do not have a copy of the • Make certain the platform is clear before TO RESET -
PUSH RESET TAB IN
instructions please obtain them from your employer, distributor or lesser, as operating the lift.
appropriate, before you attempt to operate the lift gate.
2. Be certain the vehicle is properly and securely braked before using the liftgate. liftgate is not in use.
3. Always inspect this lift gate for maintenance or damage before using it. If
there are signs of improper maintenance, damage to vital part, or a slippery In
loading and unloading.
Decal - C
platform surface, do not use the lift gate. Do not attempt your own repairs, • Do not overload, refer to capacity decals.
unless you are specifically trained.
4. Do not overload. See the Mfg. Literature and/or Rating Label on the unit for Loading Position: • Slide out liftgate
the rated load. Remember that this limit applies to both raising and lowering Out • Unfold platform
operations.
5. Each load should be placed in a stable position as near as possible to the
Storage Position: platform tip
center of the platform. • Slide in liftgate
6. Never allow yourself, a helper, or a bystander to stand in a position where an
• Raise platform MAXIMUM LOAD CAPACITY
unstable load might fall on them. Do not allow any part of your or your helper’s Up 24"
body to be placed under, through, or around any portion of the moving lift gate,
or in a position that would trap them between any parts when the lift gate is
operated. Lift Max Capacity Load
XXXX LBS.
on Platform CENTER LOAD ON PLATFORM TO AVOID
7. This lift gate is intended for loading and unloading of cargo only. Do not use Down Platform PERSONAL OR PROPERTY DAMAGE
this lift gate for anything but it’s intended use. The lift gate is not equipped
with a back up system to prevent falling in the event of a failure.
Decal - A Decal - B Decal - D
ELECTRICAL SYSTEM IS PROTECTED BY

A RESETTABLE CIRCUIT BREAKER. SEE
OWNER'S MANUAL AND DECAL LOCATED
ALWAYS STAND CLEAR
AT THE BATTERY.
OF PLATFORM AREA
Decal - E
Decal - G
READ AND UNDERSTAND ALL INSTRUCTIONS AND WARNINGS BEFORE USE.
Decal - F
Read all Decals and Owner's Manual before operating liftgate

LIFT GATE USE HANDLE TO OPEN & CLOSE DOWN:
SHUT-OFF ALWAYS STAND CLEAR Step on switch 1 and hold - wait between one and three seconds
before you step on switch 2.
TO BE TURNED OFF
WHEN LIFT IS NOT
OF PLATFORM AREA WHEN
UP:
IN USE OPERATING THE GATE 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
Decal - H Decal - I 2 1
If both switches are not activated within three seconds start over.
Decal - J
Decal - K
Left Side
(Street Side)
D G F Right Side
(Curb Side)
G F
J
E D
A
K H
Rev.1.5 26
7.5 Quick Check List

1. Operate the liftgate throughout its entire operation and check for noise and damage such as bent
parts or cracked welds.
2. Inspect all welds and fasteners that attach the mount frame to the truck. All pins and bolts that
connect the lift arm to the mount frame and to the platform.
3. Visually inspect the hydraulic lines for damage, scratches, bending or leakage.
4. Inspect the cylinders for leakage and that the cylinder pins are secured with lock bolts.
5. Check the oil level when the platform is down at ground level. The level should fall between the
markings 5 and 7 on the tank. We recommend replacing oil after the first 1200 cycles, after that on a
yearly basis in the fall before winter begins.
6. Check for oil leakage around the power pack and inside mount tube. Tighten or replace components
if needed. If you perform work on any hydraulic components bleed the air out of the system by
operating all functions several times.
7. Check all electrical connections. Clean and protect battery terminals and check for tightness.
8. Inspect all the terminals on the solenoid-operated valves at the port of the cylinder. Lubricate the
terminals for better protection from oxidation if needed. Please check the valve block on the back of
the main tube and its connections additionally.
9. Grease all zerks on the lift gate and make sure they all take grease. Sometimes it helps to operate
the lift gate while you do this. There are 14 zerks.
10. Test all the lift gate functions, if possible with maximum loads placed according to load diagrams.
11. Check the function of the pressure relief valve.
12. When performing daily checks and you find any kind of damage that can make the use of the liftgate
dangerous, it must be repaired before using. All repairs should be made by an authorized technician.
Use only original spare parts. If in doubt contact your PALFINGER Liftgates distributor or call
PALFINGER Liftgates directly.
Do not cover up any accidents or damage; it can be dangerous for you and your co-workers.
Rev.1.5 27
8 Troubleshooting
Dangerous injuries are possible from tools short circuiting main battery connections.
Every time you are finished troubleshooting, close the rubber cover on the curbside of the mount
frame. REINSTALL THE METAL CLAMP ON THE RUBBER COVER WHEN FINISHED.
Please check the following points before looking for faults:
 Please change oil after working on hydraulic unit (removal of valves, opening of cylinder etc.)
 There is a possibility of injury if somebody other than an authorized technician works on the electrical
system!
 Injuries are possible if short circuits are caused by tools on the main battery connections.
8.1.1 Liftgate will not power on.

1. Check the shut off switch.
Turn ON the ON/OFF switch located inside the vehicles cab (Truck) or control box (Trailer).
Up
Tilt ILUK / ILU
operating the lift.
Out
Storage Position:
• Unfold platform
platform tip
On-Off
Up
• Raise platform
24" Switch
Lift Max Capacity
on Platform
Load
Down Platform

Rev.1.5 28
2. Check the circuit breaker at the main batteries.

Every truck has a circuit breaker on top of the main batteries or if you have an auxiliary battery kit as
shown in the illustration below.
If circuit breaker reset tab is exposed, push the tab back in as shown.
Buss
Bar
Circuit Breaker
Location
Circuit Breaker at Truck Batteries or Auxiliary Battery Box
RE
SE
T
Reset Tab
3. Are the vehicle batteries charged?

Check batteries and the truck/trailer charging system. Start truck and run engine in fast idle for
charging the batteries. If liftgate starts working, recharge and load test batteries. Measure battery
voltages: Flooded Batteries = 12.6V; AGM Batteries = 12.8V
Rev.1.5 29
4. Check the fuse at the batteries.

Check for burned fuse and replace with the same amperage fuse.
DO NOT use higher amperage fuse.
Fuse Holders
Replace fuse when metal

Hydraulic bridge is broken
Power
Unit Control
Board
5. Is the connection to ground on hydraulic power unit OK?

Is the ground connection from the liftgate to vehicle properly grounded?
6. Check the oil level in the hydraulic power unit.

The power unit is located inside the enclosure mounted on the mount frame. To access the oil
reservoir, remove the enclosure cover. The oil must be 1” down from the top of the reservoir.
7. Are there any damages on mechanical or electrical parts (such as damaged cables)?
Perform a visual inspection of all electrical wiring and mechanical components.
Rev.1.5 30
8.1.2 ON-OFF Switch is On, But All Functions are Dead

Possible Malfunctions:
1. Short in hand held remote or its wiring.  Unplug hand controls.
2. Short in Control box wiring.  Remove Plug J-30 (Reference Electrical Schematic to
location Plug J-30).

3. After disconnecting plugs, reboot board by unplugging J-1 for 5 seconds and plug it back.
8.1.3 Warning Lights ON, after ON-OFF Switch is Turned OFF

1. B-15 Sensor is not working.
Make sure the wire strain relief is alwas parallel with the top of the platform.
8.1.4 Platform Tilts Down Before it Reaches The Ground

1. Adjust B-13 liftarm sensor.
2. B-13 is not working.  Unplug J41 (Gate operates without sensor but losses
auto tilt function).
If gate is still not working, take Truck/Trailer to a repair station
Rev.1.5 31
8.2 Electrical Wiring – Batteries – Truck/Trailer

*Resettable Circuit Breaker: 150 Amp Min. Replace with same amperage breaker when necessary.
Ground: For optimal grounding, ground all batteries and power units to the body side rails of the vehicle.
NOTICE: DO NOT attempt to jump in-line fuses with other objects other than the specified fuse.
Do not increase the amperage rating of fuse. Serious harm to the liftgate will result when standard practices are not followed.
Wires #2 and #4
go to postitive (+)
In-Line
Fuse
Wires #1 and Gr/Yl

go to ground (-)
Main
*Resettable Batteries
Circuit
Breaker
Ground
2Ga Power Cable

From Liftgate (+)
2Ga Ground Cable
From Liftgate (-)
Wiring Diagram – Truck
Wires #2 and #4 Wires #2 and #4

*Resettable go to postitive (+) go to postitive (+)
Circuit
Breaker *Resettable
Circuit
Breaker
In-Line
Fuse
Wires #1 and Gr/Yl
Dual In-Line go to ground (-)
Pole Fuse
Single Wires #1 and Gr/Yl
Pole go to ground (-) Socket
Socket
*Resettable
Circuit *Resettable
Breaker Circuit
Breaker
Auxiliary Auxiliary
Batteries Batteries
Ground Ground
2Ga Power Cable 2Ga Power Cable

From Liftgate (+) From Liftgate (+)
2Ga Ground Cable 2Ga Ground Cable
From Liftgate (-) From Liftgate (-)
Wiring Diagram – Single Pole – Trailer Wiring Diagram – Dual Pole – Trailer
Rev.1.5 32
8.3 Electrical System Codes
Code: Description: Reason: Solution 1: Solution 2: Solution 3: Solution 4:

System OK /
System OK / Control System: OFF System OK / Control System: OFF Control System: OFF -- -- --
System OK /
System OK / Control System: ON System OK / Control System: ON -- -- --
Control System: ON
Check J-1 & J-2 power
cable at PC board Check the battery Motor could have worn
Low Voltage Voltage J1 Pin 2 too low and battery for tight condition / battery carbon brushes / motor
connection, oxidation charged could be bad --
and damage.
Liftarm sensor (B-13): Broken J41-C shorted; J41 pin BLUE: Check sensor for signal
wire getting more than 5 Volts Check adjustment B-13 Blue wire with platform Change B-13 liftarm
wire, short --
(right upper location J41) 10"-12" off ground sensor
J41-C shorted; J41 pin BLUE: Check adjustment B-15 Unplugged, plugged in Change B-15 platform To temporary by-pass,
Platform sensor (B-15): Broken
wire getting more than 5 Volts platform wrong location sensor jump Black to Blue
wire, short
(right upper location J41)

cable at PC board Check warning light
Power consumption J3 Pin 7 --
Short on warning lights and battery for tight --
to high cables for damange
connection, oxidation
and damage.
Power consumption J11 Pin 1 cable at PC board Check cab cut off/
Short in cab Switch, control --
to high and battery for tight warning light cable for --
system
connection, oxidation damange
and damage.
cable at PC board Unplug wires one by Repair cables,
General power consumption --
General Short in electric wiring and battery for tight one, check for correct connections, check for
to high
connection, oxidation plug location burnt or crushed wires
and damage.
Check J-1 & J-2 power Possible short in Thermo
Check the battery Possible short in diode
Defect in motor solenoid cable at PC board Switch inside motor
Power consumption J1 Pin 3 condition / battery jumper wire on Motor
during lifting and battery for tight Bypass and test, replace
to high charged Solenoid: Remove
connection, oxidation Thermo Switch
Jumper
and damage.
Fuse 15A damaged on power Check fuses at power Check fuse holder
Defective fuse J1 Pin 2 Replace fuse with same -- --
pack (J1, Pin 2) pack
amp fuse
During opening, an error was Check J-1 & J-2 power
recognized on the valve spool for Power consumption J1 Pin 3 cable at PC board Check the battery Change coils or
Check ohm reading
opening (S3/S4) or at the motor to high; ohm reading J4 pins 14 and battery for tight condition / battery cables
of the coils
solenoid. NOTE: ONLY APPLIES have changed connection, oxidation charged
TO ILK CANTILEVER LIFTGATE. and damage.
During closing, an error was Check J-1 & J-2 power
recognized on the motor solenoid Power consumption J1 pin 3 too cable at PC board Check the battery Check ohm reading
Change coils or
or on the valve spool S-5. high; ohm reading J1 pin 12 has and battery for tight condition / battery of the coil motor
cables
NOTE : ONLY APPLIES TO ILK changed connection, oxidation charged solenoid
CANTILEVER LIFT GATE. and damage.
During lowering, an error was Resistance J1 pin 12 has Check resistance of the Change valve coils and Change coils or
Check ohn reading of
recognized on S-1/S-2 lowering changed; ohm reading J4 coils cables
cables the coils
valves or valve spool S-5 pins 15 have changed
Emergency mode active (all logic Activate by pressing OPEN and Deactivate by turning
fuctions and comfort fuctions are LOWERING button (and Second cab switch or on off --
-- --
switched off) Hand if in use) simultaneously switch OFF then back
for over 10s ON
Error diagonstic mode active Attached service plug -- --
-- --
NOTE: ILK, B-15 Sensor wire points To Clear Code:

NOTE: B-13 sensor wire points
toward ground when platform 1. Unplug J-11 and plug
toward front of vehicle
strored vertical back in
NOTE: ILF, ILU, ILUK b-15 sensor NOTE: Purple side of sensors
2. Cab switch off and on
wire points toward front of vehicle always face outward, where you
to clear code
when platform is up at bed level can see purple
Code Display
Rev.1.5 33
8.4 Connector Overview
Port Number Port Designation

J1 Power Pack
J1-A Valve
J2 Not Used
J3 Warning Lights & Foot Controls on Platform
J4 Valves
J11 On/Off Switch
J30 Control Box
J31 Hand Held Remote
J32 Not Used
J41-A B-13 Sensor
J41-B Not Used
J41-C B-15 Sensor
J42 Valves
JB Not Used
JK Not Used
JP PC Diagnosis
Rev.1.5 34
8.5 Cross Test on Single Pole Plug Charge System
Testing of full system using a battery load tester. Start with testing each individual battery on both tractor
and trailer before proceeding to check the system:
A. 12V lead from tractor coil cord

A B. Center (+) plug on front of trailer
C. Trailer Ground on front of trailer
D. Tractor chassis ground
B C
BC
D C
+ - + - + - + -
C B B
1. Tractor Test:
 Ground battery load tester on tractor chassis point (D)
 Connect positive load tester cable on positive pole of single pole plug at end of tractor coil
cord (A)
 Run load test- This will test entire circuit on tractor including ground
2. Trailer Test:
 Ground battery load tester on trailer chassis point (C)
 Connect positive cable on positive pole of single pole plug receptacle on trailer (B).
 Run load test- This will test entire circuit on tractor including circuit breakers and ground
between trailer batteries and trailer chassis.
3. Tractor and Trailer Charging system test while connected:
 Ground battery load tester on tractor chassis point (D)
 Connect positive cable on positive pole of single pole plug receptacle on trailer (B).
 Run load test- This will test entire circuit on tractor and trailer including ground between
tractor, trailer, and circuit breaker on trailer.
A simple low amp voltage test at the front of the trailer or at the tractor will not show insufficient connections
or ground problems.
Rev.1.5 35
Control Box
Rev.1.5
ILUK 33/44/55/60
8.6 Electrical Schematic
Circuit
Board
Power Pack
ILUK Electrical Schematic
013033-02.01
15939 Piuma Ave. Cerritos, CA 90703
Owner’s Manual
36
8.7 Hydraulic Schematics
Functions:
Lift: M+S1+S2
Lower: S1+S2+S5+S11
Tilt Up: M+S5
Tilt Down: S3+S4
Slide Out: M+S8
Slide In: M+S7
S1, S2 on lift cylinder and S7, S8 on push pull valve block are double acting release valves:
They have to be activated for fluid to go through them in either direction
To slide out S8 is activated to allow fluid to both sides of retractable cylinders
To slide in S7 is activated to allow fluid to piston rod side of retractable cylinders ILUK 33/44/55/60
3-Valve Hydraulic Schematic
15939 Piuma Ave. Cerritos, CA 90703
Rev.1.5 37
8.8 Functional Description of Hydrualics When Operating
The following operating functions are relating to Section 8.6. Please use the schematic to understand the
specific functionality of the ILUK liftgate.
8.8.1 Slide Out Function

 As soon as the Motor starts to run, valve S8 is energized.
 Oil pressure on input “A” sets exits “Av” and Bv” at the valve block under pressure.
 The surface at the end of the piston rod on input “B” is larger than on the shaft at input “A”.
 This creates a stronger force at the piston rod (“B”) than at the shaft (“A”).
 This factor forces the cylinder to extend.
 The lift gate will slide out to the end of the rails.
8.8.2 Lower Down and Auto Tilt Function

 The shift valve S5 at the pump and the solenoid release valves S1 and S2 at the cylinders will get
energized. In addition the leaking down stop valve S11 in the back of the mount frame is also
energized.
 The gate is designed to lower down by gravity. It will push the hydraulic oil out of the lift cylinder into
the reservoir. The oil passes the solenoid release valves S1 and S2. It also has to pass the energized
S11 valve in the back of the mount frame and the shift valve S5 at the pump.
 When the platform touches the ground the auto tilt function will get activated (B-13).
 Solenoid release valves S3 and S4 at the tilt cylinders will be activated.
 The existing oil in the tilt cylinder runs back through the energized solenoid release valves S3 and S4
and the energized shift valve S5.
 Speed of tilting down will be reduced by passing through the restrictor R5.
8.8.3 Level Out Activity

 Motor starts running and S5 valve is energized.
 Oil pressure on input “B” sets pressure on exits “BK” at the valve block.
 The Oil pressure on exit “BK” at the valve block sets the input “B” at the tilt cylinder on pressure.
 The platform will tilt up and get in a level position. When the platform is leveled, the B-15 Platform
sensor shuts down the shift valve S5 and activates the S1 and S2 valves at the Lift Cylinders which
directs the fluid into the Lift Cylinders. This causes the platform to raise.
Rev.1.5 38
8.8.4 Lift Up Function

 Motor starts running and double locking release valves S1 and S2 are energized.
 The pressure is on input “A” at the valve block. The oil passes the S11 valve and sets pressure on exit
“AH”.
 The energized double locking release valves S1 and S2 forces the fluid to push the lift cylinders to
extend. The platform raises up.
8.8.5 Slide In Function

• Motor starts running and S7 valve is energized.
• Oil pressure on input “A” sets pressure on exits “Av” at the valve block.
• The Oil pressure on exit “Av” at the valve block sets pressure on input “A” at the cylinder.
• The energized valve S7 is allowing the oil at the bottom of the piston rod to get back through the S5
into the reservoir.
• The pressure on the end of the shaft will force the piston rod to retract.
• The liftgate will slide in under the body.
Rev.1.5 39
8.9 ILUK Push Pull Valving
Rev.1.5 40
9 Technical Data
9.1 Torque Specifications

Imperial Fasteners
Fastener Grade 2 Grade 5 Grade 8
Size Torque (ft-lbs) Torque (ft-lbs) Torque (ft-lbs)
Coarse Fine Coarse Fine Coarse Fine

¼” 4 4.7 6.3 7.3 9 10
5/16” 8 9 13 14 18 20
3/8” 15 17 23 26 33 37
7/16” 24 27 37 41 52 58
½” 37 41 57 64 80 90
9/16” 53 59 82 91 115 129
5/8” 73 83 112 128 159 180
¾” 125 138 200 223 282 315
7/8” 129 144 322 355 454 501
1” 188 210 483 541 682 764
Metric Fasteners
Fastener Class 8.8 Class 10.9 Class 12.9
Size Torque (Nm) Torque (Nm) Torque (Nm)
Coarse Fine Coarse Fine Coarse Fine
M5 5.75 - 8.1 - 9.7 -
M6 9.9 - 14 - 16.5 -
M7 16.5 - 23 - 27 -
M8 24 - 34 - 40 -
M8x1 - 25 - 35 - 42
M10 48 - 67 - 81 -
M10x1.25 - 49 - 68 - 82
M12 83 - 117 - 140 -
M12x1.25 - 88 - 125 - 150
M14 132 - 185 - 220 -
M14x1.5 - 140 - 195 - 235
M16 200 - 285 - 340 -
M16 x1.5 - 210 - 295 - 350
M18 275 - 390 - 470
M18 x1.5 - 305 - 425 - 510
M20 390 - 550 - 660 -
M20x1.5 - 425 - 600 - 720
M22 530 - 745 - 890 -
M22 x1.5 - 570 - 800 - 960
M24 675 - 960 - 1140 -
M24x2 - 720 - 1000 - 1200
Rev.1.5 41
10 Needed Information for Ordering Spare Parts and Repairs
10.1 Ordering Spare Parts

In order to assure quick delivery of spare parts, please always state the following information when making
orders:
1. Liftgate model & serial number. Parts manuals are available at www.palfinger.com if necessary.
2. Designation and number of the spare part in accordance with the spare parts list.
3. Designation and number marked on the individual component (if available).
10.2 Repairs
Parts sent to Palfinger Liftgates to repair must be accompanied by a letter (in separate cover) giving details
and scope of the repairs required.
11 Warranty
Palfinger Liftgates provides warranty as part of its conditions of delivery. Spare part deliveries are first of all
billed. Palfinger Liftgates then issues credit for all or part of the invoiced sum when Palfinger Liftgates has
been able to determine that the warranty claim is justified as defined by its warranty conditions. Palfinger
Liftgates does this by inspecting the defected parts which are sent back to Palfinger Liftgates freight-prepaid
as well as the written description of the problem which must have been filled out in full.
The parts that are sent back to Palfinger Liftgates, marked with serial number and address, become
Palfinger Liftgates’ property if the warranty claim is accepted.
All warranty claims must be received within 30 days of repair or replacement. Including the following
information:
1. Liftgate model.
2. Liftgate serial number.
3. Description of problem.
4. Itemized bill of repair with breakdown of number of hours to perform warranty work and labor
changes per repair.
5. Parts used for repair with Palfinger Liftgates part number.
6. RMA#.
7. Contact at Palfinger Liftgates, if applicable.
Model Pump and Motor Cylinders Hardware Control System Hydraulic

ILUK
2 yrs 3 yrs 2 yrs 2 yrs 2 yr
33/44/55/60
Warranty Coverage Schedule1
1 Effective: Aug. 2010
Rev.1.5 42
12 Contact Address
15939 Piuma Ave

Cerritos, CA 90703
Phone: (562)-924-8218
Fax: (562)-924-8318
E-mail (parts order):

572 Whitehead Road

Trenton, NJ 08619
Phone: (609)-587-4200
Fax: (609)-587-4201
E-mail (parts order):

Rev.1.5 43

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OWNER’S MANUAL

ILUK 33, 3300 lbs. Capacity

ILUK 33/44/55/60 Owner‘s Manual

Information in this document is subject to change without notice.

If you received this product with damaged or missing parts,

15939 Piuma Ave.

572 Whitehead Road.

8.8 Functional Description of Hydrualics When Operating .................................................. 38

Vehicle Year Make & Model:

Liftgate Serial Number:

Liftgate Model Number:

Thank you for choosing Palfinger Liftgates.

2.2 Important Notes

2.3 General Information

The maximum loads must be observed and followed!

It is not permitted to use the tail lift:

 As an elevating work platform

Thank you for choosing PALFINGER Liftgates.

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.

Replacement manuals are available to download at www.palfinger.com.

4.1 ILUK 33/44/55/60 General Overview for Trailers

5 Maximum Load and Placing of Load on Platform

By increasing this distance the maximum load of the liftgate is decreasing.

Always stand clear of platform area when operating the liftgate.

For questions regarding operation call (888) 774-5844

ON/OFF Switch ON/OFF Switch

3. Use the Slide In switch to store the gate.

5. Turn liftgate OFF.

For questions regarding operation call (888) 774-5844

ON/OFF Switch ON/OFF Switch

Lift UP White Button

Lift DOWN Black Button

6.3 Wireless Hand Held Remote (Optional)

Slide Out (A) Slide In (B)

Note: One latch is used for both cart stops.

6.5 Foot Controls Operation (Optional)

Front Front Foot RearFoot

Rear Raise Platform

Front Foot RearFoot

7 Preventive Maintenance and Quick Check

REPAIR OR REPLACE FAULTY PARTS IMMEDIATELY

7.1 Maintenance and Care

3 zerks: Oil reservoir

Grease: Location of Grease Zerks (7 on each side, 14 total).

Remove Pull Out

Oil Drain Bolt

Extreme Cold Temperature MIL H5606 (Military Spec.)

F 2 ATG-WLH Warning: Liftgate Can Crush

Decal - A Decal - B Decal - D

ELECTRICAL SYSTEM IS PROTECTED BY

Read all Decals and Owner's Manual before operating liftgate

7.5 Quick Check List

11. Check the function of the pressure relief valve.

Please check the following points before looking for faults:

8.1.1 Liftgate will not power on.

For questions regarding operation call (888) 774-5844

ON/OFF Switch ON/OFF Switch