PLR Installation Manual - 06-2017

INSTALLATION MANUAL
& CHECK OFF SHEET

PLR 20S, 2000 lbs. Capacity
PLR 25S, 2500 lbs. Capacity
PLR 25D, 2500 lbs. Capacity
PLR 33D, 3300 lbs. Capacity
06/17
PLR 20S/25S/25D/33D Installation Manual

Document Part Number: 90-0316-000 / 16-695_90-00_00-00
ECN-M1044, Rev. 1.2, 06-12-17
Copyright © 2017 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
Technical Support
technicalapplications@palfinger.com
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
Rev. 1.2 -2-

Table of Contents
1 Manual Updates ........................................................................................................................ 5
2 Safety Information .................................................................................................................... 6
3 Important Information .............................................................................................................. 7
4 Tools For Installation ............................................................................................................... 9
4.1 Boxed Items .................................................................................................................. 9
5 General View of PLR Liftgates ................................................................................................. 10
5.1 PLR S-Model Liftgate (Single Cylinder) ......................................................................... 10
5.2 PLR D-Model Liftgate (Dual Cylinder) ........................................................................... 11
5.3 Important Dimensions ................................................................................................... 12
6 Installation Dimensions ........................................................................................................... 13
7 Platform Compatibility ............................................................................................................. 15
8 Chassis and Body Preparation - 800mm [31.50“] Liftarm ...................................................... 16
9 Chassis and Body Preparation - 900mm [35.40“] Liftarm ...................................................... 17
10 LIftgate Installation ................................................................................................................... 18
10.1 Sill Cutouts.................................................................................................................... 18
11 Bed Extension Installation ....................................................................................................... 19
11.1 Bed Extension (Weld-On) ............................................................................................. 19
11.2 Bed Extension (Bolt-On) ............................................................................................... 23
12 Liftgate Installation (Truck) ...................................................................................................... 25
12.1 Liftgate Installation ........................................................................................................ 25
12.2 Adjusting the Platform ................................................................................................... 32
12.3 Final Steps of Installation .............................................................................................. 36
12.4 Sub-frame Installation (Optional) ................................................................................... 37
12.5 Dock Bumper Installation - Weld-On (Optional) ............................................................. 38
12.6 Dock Bumper Installation - Bolt On (Optional) ............................................................... 39
13 Electrical Installation ................................................................................................................ 41
13.1 Wiring Diagram – Battery Setup .................................................................................... 42
13.2 Cable Routing ............................................................................................................... 43
13.3 Connecting Power to Liftgate ........................................................................................ 43
13.4 Wire Crimping ............................................................................................................... 44
13.5 Circuit Breaker Installation ............................................................................................ 44
13.6 Toggle Switch Installation ............................................................................................. 45
Rev. 1.2 -3-

13.7 Liftgate Shut-Off Switch ................................................................................................ 47

13.8 2-Button Hand Held Remote Control (Optional) ............................................................ 49
13.9 Wiring Diagram (Gravity Down) ..................................................................................... 51
13.10 Wiring Diagram (Power Down) ...................................................................................... 52
14 Hydraulic Schematic (Gravity Down) ...................................................................................... 53
14.1 Hydraulic Schematic (Power Down) .............................................................................. 54
15 Decal Placement and Inspection ............................................................................................. 55
16 Lubrication ................................................................................................................................ 57
17 Final Inspection (Check Off Sheet) .......................................................................................... 59
Company Information:
Company Name:
Advisor Name:
Vehicle Year Make & Model:
Liftgate Information:
Liftgate Serial Number:
Liftgate Model Number:
Date of Purchase:
Date of Installation:
Rev. 1.2 -4-

1 Manual Updates
Revision Description
v1.1  Revised Section 7 (Platform Compatibility Table, 800mm liftarm.
v1.2  Updated Section 6: Dimensions Sheets.
 Updated Section 8: Mounting Dimensions Table.
 Updated Section 11.2: Updated bolt-on hole pattern.
 Updated Section 12 (all): Updated steps and detailed instructions.
 Updated Section 12.2: Added rubber snubber on liftarms.
 Updated Section 13.9-13.10: Updated Power & Gravity down wiring schematics.
 Updated Section 14: Update PSI for single and dual cylinders.
Rev. 1.2 -5-

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 it is used to alert the user 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 it is to alert you to special instructions, steps, or procedures.)
 Always be aware of your surroundings.

 Wear eye protection at all times during installation.
 Ear protection and gloves should be used when necessary.
Rev. 1.2 -6-

3 Important Information
Before Getting Started
“READ FIRST”
The PLR liftgate is a heavy duty industrial hydraulic lifting device. Performance and reliability are
closely related to proper installation, battery cable connections, and grounding. All grounding
surfaces MUST be cleaned, prepped, and sealed per this manual. “Cut to size” cables MUST be
properly crimped and sealed as factory supplied. All connections MUST be dressed with dielectric
grease or equivalent sealer.
 Review liftgate invoice, packing slip, and installation drawing to assure delivery of correct gate and
complete delivery of accessories and optional equipment.
 Refer to Section 8 and verify that the truck/trailer has sufficient bed height and mount clearance for the
selected gate. Keep in mind that the truck/trailer can settle several inches depending on suspension,
over hang, addition of equipment and loading.
1. If the minimum bed height is not maintained the gate will not fold or unfold
2. If the maximum bed height is exceeded the gate may not reach the ground
 Read and understand the “Installation Manual” and “Owner’s Manual” in their entirety before starting
the installation.
 Refer to your truck manufacturer’s instructions before adding any auxiliary equipment. Installer is
responsible for compliance with this manual, OEM and FMVSS requirements.
 All welding should be performed by qualified personnel per AWS standards.
 Always Ground closest to your welding point to prevent arcing through moving parts or electrical parts.
 Contact Palfinger Liftgates for Special Installations not covered in this Installation Manual.
 Do not paint cylinder shafts or nylon bearings (Use non-chlorinated brake cleaner to remove over
spray)
 Final Check-Off-Sheet at rear of this manual MUST be filled out and sent to Palfinger Liftgates for
warranty activation.
 Refer to Owner’s Manual for Operation and maintenance information.
 Check the battery voltage before installation. Flooded lead acid batteries should measure 12.6V and
AGM batteries should measure 12.8V. If batteries are not at these voltages, fully charge before
installation.
Rev. 1.2 -7-

Improper operation of this liftgate may result in severe personal injury or death. DO NOT operate
unless you have been properly instructed, have read and are familiar with the procedures in this
manual. This manual has been designed to illustrate the steps needed for the basic installation of
the PLR 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 PLR series liftgate only which is designed for
different capacities and features.
1) Refer to the serial number tag on the liftgate, the tag can be found on the driver side of the Mount
Frame, as shown in Fig.1.
Liftarm
Serial
Number
Tag Mount Frame
(Driver Side)
Fig.1
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 at www.palfinger.com
For technical support, contact Palfinger Liftgates or an authorized Palfinger service center.
www.palfinger.com
Rev. 1.2 -8-

4 Tools For Installation
Metric Wrench Set Basic Screwdrivers Assorted Pliers Wire Crimp Pliers
Digital Multi-Meter Snap Ring Pliers Hammer SAE & Metric Allen key Set
½” Impact & Sockets SAE & Metric Socket Set Assorted Drill Bits Floor Jack or Equiv.
Small to medium bottle Forklift or Over Head Hand Held Grinder Paint Gun & Accessories
Jack Crane
Pry Bar 3/8 Drill Motor Grease Gun Heat Gun or Equiv.
Min. 250 Amp Welder Cutting Torch or Equiv. Safety Goggles Framing Square
4.1 Boxed Items

Installation for each boxed item can be found throughout this installation manual.
Owner's Manual Installation Manual Decal Kit

1 pc 1 pc 10 pcs
Heat Shrink,
Battery Lug, 5/16" ø1/2" x 3"L Copper
Circuit Breaker
1 pc 1 pc Bus Bar
1 pc
1 pc
For Trucks For Trailers
Toggle Switch Power Cable 8" Nylon Cable Tie Shut Off Switch
1 pc 1 pc 15 pcs 1 pc
Rev. 1.2 -9-

5 General View of PLR Liftgates
5.1 PLR S-Model Liftgate (Single Cylinder)

Single Cylinder Available Options:
 Lift Capacities: 2000 lbs; 2500 lbs.
 Power Down (Electrical) – Power (motor) assisted operation for lowering platform.
Bed Extension
Hydraulic
Power
Unit
Mount
Plate Hydraulic
Platform Power
Roll-Off Unit
Wheels
Double Action
Lift Cylinder Mount
Load Center Springs* Plate
of Gravity
Mount
Frame
Liftarm
Parallel Arm
Cart Stops
(Optional)
Platform
*No spring installed on left side for 42“ and 48“ aluminum platforms only.
Rev. 1.2 - 10 -
5.2 PLR D-Model Liftgate (Dual Cylinder)
Dual Cylinder Available Options:
 Lift Capacities: 2500 lbs; 3300 lbs.
 Power Down (Electrical) – Power (motor) assisted operation for lowering platform.
 Standard Configuration - No bumper. Fig.2.
 Center Bumper- Three piece bumper assembly positioned in the center of the mount frame. Fig.3.
 DOT Bumper- Three section bumper that meets Department of Transportation requirements. Fig.4.
 Hitch Bumper – Three piece assembly with hitch receiver and “D” rings. Fig.5.
Fig.2
Bed Extension
Mount
Plate
Hydraulic Platform
Power Roll-Off
Unit Wheels
Double Action
Lift Cylinders
Mount
Plate
Load Center Springs*
of Gravity
Hydraulic
Power
Unit
Mount
Frame
Liftarm
Parallel Arm
Cart Stops
(Optional)
Platform
PLR Liftgate Optional Configurations
Standard Bumper DOT Bumper Hitch Bumper
Fig.3 Fig.4 Fig.5
*No spring installed on left side for 42“ and 48“ aluminum platforms only.
Rev. 1.2 - 11 -
5.3 Important Dimensions

Minimum Bed Height dimensions are ALWAYS MAXIMUM LOADED TRUCK.
Maximum Bed Height dimensions are ALWAYS DRY UNLOADED TRUCK.
 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.
 Ensure trailer/truck body does not interfere with installation or operation of the PLR liftgate series.
 It is not recommended to cut, torch, or remove support materials from trailer/truck. Removing gussets,
stiffeners, light rings, or other such support structures may VOID your trailer/truck warranty.
 Call technical support before starting the installation if any questions or concerns arise on mounting
dimensions or procedures.
 Minimum clearance area required for a PLR liftgate to install on a vehicle is 30”. Clearance area should
be free of any obstructions that will prevent the installation of the liftgate, Fig.6.
35"
30"
Floor
Body Long Rail
Wooden Spacer
Chassis Frame
Fig.6
Rev. 1.2 - 12 -
6 Installation Dimensions
Trailer Chassis Dimension Sheet

Customer Information Liftgates Information:
Quote#/SO#:____________________________________________________ Model:
Company:______________________________________________________ Capacity:
Phone:_________________________________________________________ Platform Size:
Email: _________________________@______________________________ Platform Material:
Trailer Information
Trailer Specifications: Type of Body (check applicable) Type of Rear Door (check applicable)
Manufacturer: (ex. Utility) Van Flip-Up
GVWR: (ex. 68,000 lbs) Flatbed Roll-Up
Length: (ex. 53ft) Reefer Swing
Width: (96", 102") Other (specify)____________ Other (specify)________________
Trailer Dimensions
A = Bedheight: Top of trailer floor to level ground (with airbags up):........................................................................________ Notes:
B = Top of floor to bottom of trailer cross member:.....................................................................................................________
C = Rear sill height (Top of floor to bottom of buck plate): If Stepped sill complete M,N; If Tapered sill complete O, P.
M O
Flush Stepped Tapered
C M = ________ N O = ________ P
C = ________
N = ________ P = ________
D = Crossmember height:...............................................................................................................................................________
.
E = Tire to end of vehicle body:......................................................................................................................................________

F = Bogie to end of vehicle body................................................________ Sliding Suspension? Yes________ No________
If Yes complete G, H, I, K, and L dimensions
G = Inside horizontal width of sliding suspension angles:.........................................................................................________
H = Diameter of sliding suspension holes:...................................................................................................................________
.
I = Hole spacing:..............................................................................................................................................................________
J = Bottom of crossmembers to bottom of sliding ramp box, if applicable:.............................................................________
K = Rear sill face to first slider hole:.............................................................................................................................________
L = Top of floor, where liftgate platform will meet floor, to the center of the trailer slider holes:............................________
X = Eyebrow depth:.........................................................................................................................................................________
Z = Top of floor, where the liftgate platform will meet the top of the eyebrow:.........................................................________
Rear View of Trailer Z

Side View of Trailer
J
Walk Ramp (if applicable)
L D B
I C
øH K A G
X
F
E
90-9813-002_b
Rev. 1.2 - 13 -
Truck Chassis Dimension Sheet

Customer Information Liftgates Information:
Quote#/SO#:____________________________________________________ Model
Company:______________________________________________________ Capacity
Phone:_________________________________________________________ Platform Size
Email: _________________________@______________________________ Platform Material
Truck Information
Trailer Specifications: Type of Body (check applicable) Type of Rear Door (check applicable)
Manufacturer: (ex. Hino) Van Flip-Up
GVWR: (ex. 68,000 lbs) Flatbed Roll-Up
Length: (ex. 53ft) Reefer Swing
Width: (96", 102") Other (specify)____________ Other (specify)________________
Truck Dimensions
A = Bedheight:.....................................________ Loaded Bedheight:.....................................________ Notes:
B = Top of floor to bottom of frame:.............................................................................................________
C = Rear sill height:.......................................................................................................................________
D = Spring hanger to end of body (if applicable):......................................................................________
E = Air bag suspension to end of body (if applicable):..............................................................________
F = Tire to end of vehicle body:....................................................................................................________
G = Gas tank to end of body (if applicable):................................................................................________
H = Fuel filler hole to end of body (if applicable):......................................................................________
I = Bottom of frame to bottom of gas tank (if applicable):........................................................________
J = Top of floor to bottom of sliding walk ramp (if applicable):.................................................________
K = Frame Width: Width of chassis frame:..................................................................................________
L = Frame Height: Height of chassis frame:................................................................................________
Side View of Truck

Rear View of Truck
C
Walk Ramp (if applicable)
B
L J
A
G K
D I
E
F
90-9813-003_b
Rev. 1.2 - 14 -
7 Platform Compatibility
Vehicle bed heights are absolute minimum for the corresponding platform
sizes when the vehicle is fully loaded and gassed.
800mm [31.50] Liftarm
Vehicle Platform Sizes

Bed
42” 48” 54”
Height
52   
51   
50   
49   
48   
47   
46   
45   
44   
43   
42   n/a
41   n/a
40   n/a
39   n/a
38   n/a
37  n/a n/a
36  n/a n/a
n/a=not avialable
900mm [35.40] Liftarm
Vehicle Platform Sizes

Bed
48” 54” 60”
Height
56   
55   
54   
53   
52   
51   
50   
49   
48   
47   
46   
45   
Rev. 1.2 - 15 -
8 Chassis and Body Preparation - 800mm [31.50“] Liftarm
-Decrease ground clearance only to clear obstructions (i.e. fuel tanks, cross members, hitches, etc.)
WITHOUT EXCEEDING MAXIMUM “F” dimension of 25”.
- Minimum bed height is when truck/trailer is loaded to Maximum GVW (Gross Vehicle Weight).
- “F” dimension: Mount and Ground clearance always relate to each other on a set floor height. If the
“F” dimension is increased for a shorter mount clearance, the ground clearance will decrease.
1) Bed Height: Bed Height Ranges: Max=Unloaded / Min=Loaded Truck Measure from TOP of body floor
to ground. Vehicle must be on a flat leveled surface when measuring.
2) “F” Dim (Mount Frame Height): Measure from top of Mount Frame to top of body floor.
3) “K” Dim Ref. (Mount Clearance): Measure from rear of body to front edge of Mount Plates.
4) “G” Dim (Ground Clearance): Measure from bottom of Mount Frame to ground.
5) “A” Dim (Body Cutout): Measure from the rear of the sill towards the front of the vehicle.
6) “B” Dim (Body Cutout): Measure from top of the sill down to the ground.
7) 800mm [31.50”] Liftarm: Measure from center to center of pivot pins.
"K"
Mount Clearance
(Reference)
Sill
"B"
Cutout
"F" Dim.
Bed Height "A"

Max. 52"
Min. 36"
5"
"G"
Mount
Frame Ground
Clearance
Mounting Dimension Table

Mounting Dimensions for Chassis Frame
800mm [31.50“] Liftarm Cutout Dimensions
Bed Height F G K A B
(Laden) Dim. Dim. Dim. Dim. Dim.
52“-47“ 25“ 22“-17“ 25“ 17“ 16“
47“-43“ 22“ 20“-16“ 28“ 19“ 10“
43“-38“ 18“ 20“-15“ 30“ 18“ 7“
38“-36“ 17“ 16“-14“ 31“ 16“ 7“
G Dim = Bed Height – F Dim. – Mount Frame Height

Never exceed any of the dimensions from the table when installing the liftgate.
Rev. 1.2 - 16 -
9 Chassis and Body Preparation - 900mm [35.40“] Liftarm
-Decrease ground clearance only to clear obstructions (i.e. fuel tanks, cross members, hitches, etc.)
WITHOUT EXCEEDING MAXIMUM “F” dimension of 28”.
- Minimum bed height is when truck/trailer is loaded to Maximum GVW (Gross Vehicle Weight).
- “F” dimension: Mount and Ground clearance always relate to each other on a set floor height. If the
“F” dimension is increased for a shorter mount clearance, the ground clearance will decrease.
1) Bed Height: Bed Height Ranges: Max=Unloaded / Min=Loaded Truck Measure from TOP of body floor
to ground. Vehicle must be on a flat leveled surface when measuring.
2) “F” Dim (Mount Frame Height): Measure from top of Mount Frame to top of body floor.
3) “K” Dim Ref. (Mount Clearance): Measure from rear of body to front edge of Mount Plates.
4) “G” Dim (Ground Clearance): Measure from bottom of Mount Frame to ground.
5) “A” Dim (Body Cutout): Measure from the rear of the sill towards the front of the vehicle.
6) “B” Dim (Body Cutout): Measure from top of the sill down to the ground.
7) 900mm [35.40”] Liftarm: Measure from center to center of pivot pins.
"K"
Mount Clearance
(Reference)
Sill
"B"
Cutout
"F" Dim.
Bed Height "A"

Max. 56"
Min. 47"
5"
"G"
Mount
Frame Ground
Clearance
Mounting Dimension Table

Mounting Dimensions for Chassis Frame
900mm [35.40“] Liftarm Cutout Dimensions
Bed Height F G K A B
(Laden) Dim. Dim. Dim. Dim. Dim.
56“-52“ 28“ 23“-20“ 28“ 20“ 17“
52“-47“* 26“ 21“-16“ 30“ 21“ 15“
G Dim = Bed Height – F Dim. – Mount Frame Height

*Vehicle bed heights tend to lower 3”-4” when loaded.
Rev. 1.2 - 17 -
10 LIftgate Installation
10.1 Sill Cutouts

To prevent interference with the platform the vehicles sill could require notching.
Options
Sill Height Action
4” No sill notching required.
5” If not notched, platform will be offset down approximately 1”-2” from bed extension.
Over 5” Notch sill as show in Fig.7. Notches will require reinforcement, Fig.8
Rear View of Trailer
20.00" 20.00"
38.75"
Sill Height 4.25"
Sill Notches
Fig.7
2X
1/8"
Sill Notch
Fig.8
Formed Steel Plate
Reinforcement
Formed
Flatbar
Reinforce all sill cutouts with flatbar, Fig.8
Rev. 1.2 - 18 -
11 Bed Extension Installation
11.1 Bed Extension (Weld-On)

1. Mark the center of the vehicle body and the bed extension. Clamp the bed extension to the forklift
Forks, Fig.9. Maintain the bed extension centered and flush to the sill vertically and horizontally. Check
for squareness before continuing.
Floor
Body Long Rail

Wooden Spacer
Frame
90°
Forklifts Forks
Flush w/Sill
Floor
Body Long Rail

Wooden Spacer
Forklift Forks
Sill Frame
Bed
Extension
Fig.9
Rev. 1.2 - 19 -
If using a hoist, make a hole on the edge of a 3” standard channel, Fig.10. Clamp the channels to the bed
extension and attached the hoist to the 3” channels. Maintain the bed extension centered and flush to the
sill vertically and horizontally. Check for squareness before continuing.
Floor
Body Long Rail

Wooden Spacer
Frame
Hoist
90° 3" Channels

Flush w/Sill
Bed
Extension
Fig.10
Rev. 1.2 - 20 -
2. Weld 3/16” x 5” welds on each end on the bed extension. Keep 1” gap clearance on corner post seam
line, Fig.11. All other welds shall be 3/16” x 2” centered on each rib, top and bottom of bed extension,
Fig.12. Bed extension shall be flush with floor level, Fig.13.
Top of Bed Extension

Welding Areas
C
L
2" Centered
on Ribs
Seam Line 10X

(Where sill 2" 3/16"
meets corner
post)
5" 1" No Weld Gap

Centered on
Seam Line
2X
3/16"
Fig.12
Corner
Post
Bed Extension
Fig.11
Rev. 1.2 - 21 -
Sill Bottom of Bed Extension

Welding Areas
Bed
Extension
2" 3/16" 10X

Ribs
Rib
Fig.12
3/16" 2"
Centered on Ribs
Bed Extension Bed Extension
YES NO
Ground Ground
Fig.13
Rev. 1.2 - 22 -
11.2 Bed Extension (Bolt-On)
1. Determine the vehicle width, 96” wide or 102” wide. Pre-drill 19, 5/8” holes on the rear of the sill per
the dimensions above.
96.00" Wide
46.50" 46.50"
41.50" 41.50"
34.00" 34.00"
29.00" 29.00"
24.00" 24.00"
14.00" 14.00"
1.25"
7.00" 7.00"
Sill
C 19X
L ø 0.625" 1.88"
Rear View of Vehicle

Tires
96"W
102.00" Wide
49.50" 49.50"
44.50" 44.50"
34.00" 34.00"
29.00" 29.00"
24.00" 24.00"
14.00" 14.00"
1.25"
7.00" 7.00"
Sill
C
L 19X
ø 0.625" 1.88"
Tires Rear View of Vehicle

102"W
Sill
Bolt On
Hole Pattern
Rev. 1.2 - 23 -
2. Use a forklift, hoist or equivalent to support the bed extension and align the bed extension with the
pre-drilled hole pattern on the sill. Verify the bed extension is squared. Secure the bed extension to
the sill with the provided 9/16-18 x1.75” bolts and 9/16” nuts. Torque all bolts to 125 ft./lbs. min.,
145 ft./lbs. max.
Recommendation: It is highly recommended to lubricate all bolts and nuts to facilitate
installation.
Sill
Bed
Extension
13/16" 7/8"
Impact Socket Wrench
Bolt-On Bed Extension
Rev. 1.2 - 24 -
12 Liftgate Installation (Truck)
12.1 Liftgate Installation
Never work under platform without safety supports.
High heat from welding can damage components within the heated area.
Steps:
1. Hoist Platform: Unfold platform manually and clamp forklift forks, overhead crane, or equivalent to
platform. Make sure the platform is secured. Always maintain the platform centered to the vehicles
body. Determine the pitch of the platform by referencing the Pitch Dimension Table based on the “F”
dimension and bedheight, Fig.14.
Rev. 1.2 - 25 -
Clamp "X" Floor

Secure
Dimension
Body Long Rail

Wooden Spacer
Chassis
Pitch Table Frame
"F" "X"
Bedheight Dimension Dimension
52"-47" 25" 2"
47"-43" 22" 1"
43"-38" 18" 0"
38"-36" 17" 0"
Fig.14
"F"
2" Pitch Bedheight Dimension
52"-47" 25"
1" Pitch
"F"
Bedheight Dimension
47"-43" 22"
"F"
Zero Pitch Bedheight Dimension
43"-38" 18"
38"-36" 17"
1a. Maneuver the liftgate under the vehicle and position both liftarms flush to both the bed extension
upstops and the underside of the bed extension. Measure the gap between the bed extension and
platform to confirm the gap is within the acceptable range, Fig.15.
Rev. 1.2 - 26 -
1/8"-1/4" Bed Extension

Acceptable Gap Upstops
(both sides)
Maintain Platform
and Bed Extension Leveled
Bed
Extension
Platform Lift Arm

Main
IMPORTANT!
Liftarms Touching Upstops and
Bottom of Bed Extension
Fig.15
1b. Clamp Platform: Clamp 3” channels over the bed extension and platform on the street side and
curbs side of the bed extension so the relationship between the bed extension and platform is
locked and maintained throughout the installation procedure, Fig.16.
Rear Edge of
Bed Extension
Front Edge
of Platform
Clamp
3" Channel Clamp
Fig.16
1c. Verification: After clamping platform, verify and confirm the following before proceeding: Fig.17.
Rev. 1.2 - 27 -
1 Bed extension and Platform are even.
2 Both liftarms are flush with bottom of bed extension.
3 Both liftarms are flush with bed extension upstops.
4 Both shackles are flush with platform stop bolts.
1 2
Bed Extension
Upstop
3
Platform
Stop Bolt Shackle
Liftarm
Shims
(Washers)
IMPORTANT!
Bolt Head Touching Shackle
Fig.17
2. Set “F” Dimension: “F” Dimension should be determined from Sections 8 and 9 of this manual. Use a
floor jack or equivalent to set the mount frame to the required “F” dimension, Fig.18. Use a second
Rev. 1.2 - 28 -
jack to level out roll off wheel hitch, if necessary, Fig.19. Check for squareness vertically and
horizontally. 12V power supply may be required to release pressure on lift cylinder valve(s), if power
is required continue to the Electrical Installation in Section 13.
Floor
Body Long Rail

Wooden Spacer
Chassis Frame
"F" Dimension
90°
Roll Off
Wheel
Hitch Mount
Frame
Primary Tube
Jack
Set F-Dimension
Fig.18
Secondary Jack
(If Necessary)
Fig.19
3. Weld on Mount Plates (Tack): Make sure the mount plate is squared to the mount frame vertically
and horizontally. Install the mount plate against the chassis frame and position on the mount frame,
Rev. 1.2 - 29 -
in the shown orientation, Fig.20. Tack weld using three fillet welds 2” long on each side and on
top of the mount plate. Remove the forklift, clamps, and/or hoisting mechanism.
Weld on Mount Plates (Verify): Verify the following: One, F dimension has not changed. Two, bed
extension and platform are still squared prior to tack welding the mount plates, Fig.21. Three, cylcle
the liftgate, make sure it is operating as intended. Do not power gate hard against bed extension
while gate is only
tack welded in position.
Weld on Mount Plates (Finalize): After verification continue to 100% welding of the mount
plate to the vehicle frame and mount frame. Connect the body long rail to the mount plate by adding
an extension plate, Fig.22.
C
L
Fig.20
Mount
Plate
Chassis
Frame
Mount Extension Fig.22

Plate Plate 2x
1/4"
34" Body Long Rail
Wooden Spacer 8" Overlap

Mount Minimum
Chassis
Plate Frame Between
Mount Mount Plate
Frame and Chassis
2x
1/4"
Body Long Rail

Wooden Spacer
Mount "F" DIM.

Frame Chassis Frame
Tube
Fig.21
Under 1/4"
2x
Ride 1/4"
Guard
Secondary Primary
Jack Jack
4. Platform Adjustments (if necessary): Adjustments of the liftgate are not required when the
Rev. 1.2 - 30 -
installation procedure has been followed per this manual. In some cases, platform adjustments
could be required as not every vehicle is identical and installation variables differ from install to install.
The platform is equipped with a combination of “shims” (washers) installed on the stop bolts.
Removing a “thin” shim will adjust the platform pitch by approximately 5/8”, and removing a “thick”
shim will adjust the pitch by approximately 1-1/4”. Making these adjustments will assist in making up
for the different installation variables.
"Thin" Shim
"Thick" Shim
To make platform adjustments,
adjust shims on the bolt side
only. Any adjustments made
to the shims must be made to M24 Bolt
the left and right side of the
platform.
Rev. 1.2 - 31 -
12.2 Adjusting the Platform
Platform is heavy, use caution while handling.

Adjustment of the torsion cam applied to all platforms (steel, aluminum, or steel/alum).
Steps:
1. Torsion Cam Installation: To change the amount of platform spring assist, position the gate as
shown below with the platform resting on the platform roll-off wheels and shackles contact the
ground, Fig.23. The adjustment cam is installed with no tension when shipped, Fig.24. Verify that
the platform has a curb and driver side cam.
Platform
Roll-Off
Wheels
Fig.23
Torsion Cam Shown

in Shipping Position
Platform Main
Fig.24
Spring Plate
Shackle
Spring Short Leg
Bottom View of Main Platform
Driver Side
Spring Long Leg
.
Rev. 1.2 - 32 -
To add tension to the torsion spring, remove the adjustment cam from its shipping position, Fig.25. Next,
install the cam on the inside part of the plate on the engaged position hole. The short leg of the spring
should be in contact with the cam, Fig.26. Secure the cam with the bolt and nut. Torque the bolts to 100 ft-
lbs, Fig.27. Repeat the process for the curb side cam. Make sure the driver side and curb side cams are
installed in the same tension setting.
Rotate Cam to
Adjust Torsion
Setting
Shipping
Position
Bolt
Cam
Plate Engaged
Position
Spring Hole
Short
Leg
Nut
Fig.26
Fig.25 Shackle
Shackle
Removing Cam from Cam Adjustment

Shipping Position Inside of Plate
13/16"
Impact Socket
13/16"
Wrench
1 4
Cam
Spring 3
Short
Leg 4 different torsion settings are
Fig.27 possible after adjusting the cam.
Tension Settings:
1 = Low Tension
4 = High Tension
Torsion Settings for Aluminum and Steel Platforms:
Aluminum: Setting 2
Steel: Setting 4
Rev. 1.2 - 33 -
2. Adjust Sliding Wheel: Loosen the nuts on the wheel bracket assembly. Adjust the wheel in or out
along the wheel hitch until the platform is 5° inward. Once the wheel assembly is in set position,
secure the wheels by torqueing the six bolts to 16-20 ft/lbs. Note: Low vehicle bed heights will
require more than 5°.
5°
Adjust
Wheel
Bracket
Nuts
Wheel
Bracket
Assembly
Wheel
Hitch
3. Adjustable Rubber Snubbers: Adjust (2) rubber snubbers up to force the platform up against frame
caps to hold platform from bouncing while vehicle is moving. Make sure there is a ½” gap between
the frame cutout and the platform. Also make sure the rubber snubbers are adjusted so the gate
does not rub on other components during the opening and closing sequences.
Platform
3/4"(19mm)
Wrench
Liftarm
0.50" Gap
Adjustable
Rubber
Snubber
Liftarm
Rubber
Snubber
Use a 3” channel (each side) as a platform store stop where frame caps cannot be installed.
Weld the channel on the inside part of the chassis/sub-frame
"
24
Platform
3" Channel
Square Cut Chassis

24
"
or Sub-Frame Channel
2X
3/16"
Rev. 1.2 - 34 -
4. Frame Cap: Cap both frame cut outs with two pieces of ¼” flat bar and two 2”x3”x3/16” angles.
Install the 2” side of the angle on the outside of the frame. Weld components to the chassis and the
body long rail. Flatbar may not be required if the frame cut out does not have a step.
Note: Palfinger Liftgates does not supply cap materials. All material must be supplied by end
users.
Flat Bar Angle

3.00" Rear of Vehicle
3.00"
H"
1/4"
H" to be determined by 2.00"
frame cut out
Wooden Spacer
Chassis
Vehicle Frame Cutout
3/16"
2"x3"x3/16"
Angle
1/4" Thk
Flat Bar
Sill
Body Long Rail

Wooden Spacer
Chassis
2"x3"x3/16"
Angle
1/4" Thk
Flat Bar
Rev. 1.2 - 35 -
12.3 Final Steps of Installation
1. Battery Connect: Connect battery cable to batteries or aux batteries to power the liftgate. Refer to
Electrical Installation on Section 13.
2. Cycle Gate: Cycle gate several times to assure proper alignment.
3. Weld Gate: Complete welding of gate. Weld all contact areas 100% with ¼” fillet welds.
4. Safety Chain: Only applies to the single cylinder PLR models. The bed extension is equipped
with a hook and chain to safely secure the platform. When the platform is in stored position, secure
the hook to the platforms plate on the platforms main section, as shown in Fig. 28.
Bed
Extension
Platform
Plate
Safety Hook
Chain
Fig.28
Single
Cylinder
Under View of
Bed Extension
Rev. 1.2 - 36 -
12.4 Sub-frame Installation (Optional)
Trailer installations require a sub-frame to be installed prior to installing the liftgate.
Never work under platform without safety supports

Steps:
1. Sub-Frame: Position the sub-frame channels up against the trailers cross members in the orientation
shown below. Weld the sub-frame channel to multiple cross members. Use 3/16” welds to secure
the sub-frame to a minimum of four cross members.
Side View
Crossmember
Subframe
Channel
30"x14"
Trailer
Sliding
Rear Rail
Sill
Sub-frame
Weld to Cross
Channel
Multiple members
3/16" Cross
Members
Trailer Frame
w/Sub-Frame
Channels
Crossmembers
Dimension determines
the distance of the
mount plates.
2. Support Plates: Install three support plates per sub-frame channel as shown and secure the plates
with 3/16” welds.
Trailer Rear View Side View
3/16"
2X
3/16"
Support
Plate
Support Plate
Liftgate 10.50"
Mount
10.50"
Plates
3. After installing the sub-frame, follow the installation procedure in Section 12 to complete the liftgate
installation.
Rev. 1.2 - 37 -
12.5 Dock Bumper Installation - Weld-On (Optional)
Dock Bumper Strut Brace

1pc Curb Side
1pc Street Side
Dock Bumper Support Channel
1pc Curb Side 2 pcs
1pc Street Side
1. Dock Bumpers: Clamp dock bumpers to the bed extension as shown, Fig.29. Check for
squareness.Tack weld the dock bumper. Repeat process for driver side.
3/16
Vehicle
Body
Bed Extension
Fig.29
Dock Bumper
2. Dock Bumper Supports: Each strut brace has a marking for easy identification, the curb side strut has
a “C” marking and the drive side strut has a “D”, Fig.30. Position the support channels perpendicular
to a minimum of three of the vehicles cross members, move the channel horizontally for adjustment,
Fig.31. Use clamps or similar devices to hold the support channels in place. Next position the strut
against the dock bumper and support channel, clamp in place. Check for squareness. Finally,
secure all components with 3/16” welds.
Bed Vehicle Body

Extension
Cross Members
Strut Identification
Marking Location
Support
Channel
3/16"
2X
3/16"
Strut
Fig.30 Fig.31
Dock
Bumper
Rev. 1.2 - 38 -
12.6 Dock Bumper Installation - Bolt On (Optional)
Dock Bumper
1pc Curb Side
1pc Street Side Support Channel
2 pcs
Dock Bumper Strut Brace

1pc Curb Side
1pc Street Side
Clamp Washer
8 pcs
Hex Head Captive Screw Flange Lock Nut

9-16"-18 X 1.75" 9/16-18
16 pcs 16 pcs
Steps:
1. Dock Bumpers: Use four (4) bolts and four (4) nuts to mount the dock bumper to the bed extension,
Fig.32. Torque nuts to 125 ft. /lbs. minimum. Make sure the dock bumper is properly squared.
Recommendation: It is highly recommended to lubricate all bolts and nuts prior to
installation.
Vehicle
Body
Bed Extension
13/16"
Impact Socket
7/8"
Wrench
Dock Bumper
Fig.32
Rev. 1.2 - 39 -
2. Dock Bumper Support: Each strut brace has a marking for easy identification, the curb side strut has a
“C” and the drive side strut has a “D”, Fig.33. Join the support channel to the strut using a set of
bolts, clamp washers and flange nuts, Fig.34. Do not tighten nuts completely as adjustment to the
support channel could be required.
13/16"
Impact Socket
Support
Channel
Strut Brace
Strut Identification
7/8" Marking Location
Wrench
Fig.33 Fig.34
3. Bolt Assembly: Secure the strut support to the dock bumper with a set of bolts, clamp washers, and
flange nuts, Fig.35. Adjust the strut brace by moving it vertically along the dock bumper and also the
support channel, horizontally, along the vehicles cross members for best positioning. Check for
squareness. After tightening all bolts in place, weld the support channel to the bottom of the vehicles
cross members. A minimum of three cross members should be welded to the support channel,
Fig.36. Torque nuts to 125 ft. /lbs. minimum.
13/16" 7/8"
Impact Socket Wrench
Support Channel
Weld to
Cross Vehicle
Members Body
Bed Extension Crossmembers
Bed Extension
Strut Brace Support

Channel
3/16"
2X
3/16"
Dock Bumper
Strut Brace
Fig.35 Dock Bumper

Fig.36
Rev. 1.2 - 40 -
13 Electrical Installation
Any deviation from Palfinger Liftgates’s recommended power setup will void warranty and product
liability unless you have a written confirmation by Palfinger Liftgates that allows you to do specific
changes.
 Never exceed rating of existing fuses located at the battery, control board and/or the pump and
motor which may result in serious damage to the equipment.
 Never jump the 150 Amp circuit breaker at the batteries unless otherwise instructed by the
Palfinger Liftgates technical support group.
 Assure all connections are tight and securely sealed.
 Heat shrink all cable connection.
 Never secure a cable in a way where it can make contact with other wiring, brake, fuel, or air
lines etc. or get pinched against other objects.
 2 gauge cable, minimum, is required throughout the motor circuit.
 When working on the electrical installation, remove any jewelry, tools, or components that
are conductive to prevent any damage or injuries.
 Insure that all wiring is secured and away from heat sources, sharp corners/edges, and
abrasion from moving components during the operation of the liftgate and vehicle.
Rev. 1.2 - 41 -
13.1 Wiring Diagram – Battery Setup
*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.
*Resettable
Circuit
Breaker
Single *Resettable
Pole Circuit
Socket Breaker
*Resettable
Circuit
Breaker
Ground
Auxiliary
2GA. Liftgate Batteries
Power Cable Main Batteries
Ground
2Ga Power Cable

From Liftgate (+)
2Ga Power Cable
From Liftgate (+)
Wiring Diagram – Truck Wiring Diagram – Single Pole - Trailer
*Resettable
Circuit
Breaker
(-)
(+)
*Resettable
Circuit Aux.
Dual Breaker Batteries
Pole
Socket
Ground
2Ga Power Cable

From Liftgate (+)
Wiring Diagram – Dual Pole - Trailer
Rev. 1.2 - 42 -
13.2 Cable Routing
1. The use of wire loom is highly recommended to protect and facilitate cable routing. Wire loom not
supplied.
2. Route all cables along the wooden spacer and through the outside of the U-bolts or on the inside
part of the channel.
3. Secure the wire along the wooded spacer with insulated cable clamps.
Do not tie electrical cables along with hoses.
Insulated
Cable
Clamps
Body
Long
Sill
Wooden
Spacer(s)
Cable Routed
Outside of U-Bolts
w/Slack
Chassis
Frame
U-Bolt
Cable Routed
on Inside of Channel
13.3 Connecting Power to Liftgate

1. Remove the cover from the Hydraulic Power Unit enclosure by removing the two wing nuts.
Insert one end of the power cable through the indicated opening on the hydraulic power unit
enclosure. Remove the nut from the solenoid post and attach the power cable to the post. Torque
the nut to 3 ft/lbs. Route the other end of the power cable to the circuit breaker by the batteries.
NOTE: Do not disconnect any of the pre-installed wires on the solenoid or motor.
To
Circuit Torque: 3 ft/lbs [4 Nm]
Breaker
Feed Power Cable
Through Here
Power
Cable
Solenoid
Post
Wing Hydraulic
Solenoid Nuts Power Unit
Enclosure
Rev. 1.2 - 43 -
13.4 Wire Crimping
All grounding surfaces MUST be cleaned, prepped, and sealed per this manual. “Cut to size”
cables MUST be properly crimped and sealed as factory supplied. All connections MUST be
dressed with dielectric grease or equivalent sealer.
Battery Cable Crimping

1. Prepare the wire to be crimped. Straighten out the exposed copper wire and insert into the battery
terminal.
2. Use a crimping tool designed for crimping battery terminals for best results. The use of other tools
could possibly damage the battery terminal and make poor connections between the wire and
terminals.
3. Slide the provided heat shrink over the battery terminal and cable to seal the connection.
Heat Source
Heat Shrink
Battery Terminal
Crimp Tool
Prepare Crimp Seal
13.5 Circuit Breaker Installation

1. Battery Mount: Attach the bus bar to the circuit breaker on the BAT post. Mount the circuit breaker
securely on the positive terminal post of battery, Fig.37.
2. Battery Box Mount: When mounting the circuit breaker in a battery box, connect a 2 gauge jumper
from the BAT post on the circuit breaker to the positive post of the battery, Fig.38.
3. Connect the liftgates 2 gauge power cable to the AUX post on the circuit breaker.
Battery Mount Battery Box Mount

2 Gauge Cable from
Hydraulic Enclosure
Jumper
AUX
Post
Circuit Breaker
Location
Buss Bar To
Positive (+)
Battery
Terminal
Battery
BAT Box
Post
Fig.37 Fig.38
Rev. 1.2 - 44 -
13.6 Toggle Switch Installation
The Toggle Switch is weatherproof from factory, do no substitute or tamper with the switch.
Determine location for fixed toggle switch on corner post in a way that the operator can view the
platform and surrounding areas while operating the liftgate. Place toggle switch in a horizontal
position
Steps:
Roll Up Door Vehicles
1. Mounting Hole Pattern: Locate area on rear curb side post of body where switch can be reached by
the operator from ground. Position the holes approximately 24” up from vehicles floor. Drill two 5/32“
(.156“) holes spaced at 1-3/4“ vertically, and one 7/8” hole, centered to the two 5/32““ holes, for the
switch cable harness, Fig.39.
2. Wiring: Route cable harness through rear post and down to the hydraulic power unit. Heat shrink or
protect all connections. Use cable clamps to keep the cable clear of all moving parts. Reference the
wiring diagrams in Sections 13.9-13.10
3. Operation: Verify all operations are functional as intended. Secure the switch to the corner post with
the two #10-24 x 1” self-tapping screws.
IMPORTANT: Screws must be hand tighten, do not use power tools to tighten screws.
Mounting Hole Pattern

ø7/8"
1-3/4"
7/8"
2X
ø5/32"
Sill 24" Approx.
Bed Extension
Corner Post
(Curb Side)
Fig.39
Rev. 1.2 - 45 -
Stake Bed Vehicles
1. Mount Switch: Mount toggle switch to dock bumper strut using two #10x1-1/2” self-tapping screws.
Dock
Bumper
Strut
Sil
l
Be
dE
xte
ns
ion
Dock Bumper
2. Route Wire: Route the toggle switch harness along the vehicle body down to the pump and motor.
To prevent damage to the harness, properly secure the harness and keep cleared from any moving
liftgate parts.
3. Connect wires: Reference Sections 13.9-13.10 for wiring according to your liftgates specificaitons.
4. Check Switch Operation: Verify that the up and down functions on the toggle switch operate as
intended.
5. Seal Connections: Heat shrink and seal all connections, if applicable.
Rev. 1.2 - 46 -
13.7 Liftgate Shut-Off Switch
Liftgate Cab ON/OFF Switch MUST be installed and in clear view of driver.
1. Mounting Switch:
Truck Application: Install the liftgates shut off switch on the vehicles dashboard in clear view of the
driver and within reach from the ground, Fig.40.
Trailer Application: Install the shutoff switch on the dock bumper strut, if applicable, or use the
faceplate to install the switch on the vehicles body as shown (faceplate requires a 2” hole to be
drilled on vehicle body for installation), Fig.41.
Decal: Apply the accompanying decal in the surrounding area of the switch.
Rocker Switch
Shutoff Switch
Location for Trucks
Decal Fig.40
Shutoff
Decal Switch
2" Drilled Hole
on Body
Switch
Faceplate
Decal
Strut
Vehicle
Shutoff Switch Body
Trailer Shutoff Switch Fig.41 Trailer Shutoff Switch

on Dock Bumper Strut on Vehicle Body
2. Route Wire: Route and secure the control wire cable every 12 inches against the frame with frame
clamps or equivalent along the frame to pump & motor box.
3. Check Wire Clearance: Verify wire is clear of all moving parts and securely tied up.
4. Cover Connections: Heat shrink or protect all connections.
5. Wiring: Reference Sections 13.9-13.10 for wiring according to the liftgates specification’s.
Rocker switch shall not be installed outside the truck cab.
Inspect and test all electrical connections, wiring and the different functions to
make sure that the electrical installation is complete.
Rev. 1.2 - 47 -
Routing Switch Harnesses to Pump and Motor
1. Route each harness to the hydraulic power unit enclosure and secure harnesses with the supplied
cable ties. Keep harnesses away from sharp corners and moving parts.
2. Feed the harnesses through the cable entry slots as shown for each component, Fig.42.
3. Wire switches accordingly per Wiring Diagrams in Sections 13.9-13.10.
Power Cable
Toggle Switch
Cab Shutoff Switch Shutoff Switch Fig.42

(Truck) (Trailer)
OR
Rev. 1.2 - 48 -
13.8 2-Button Hand Held Remote Control (Optional)
2-Button
Hand Held Remote Mounting Screws
Hand Held Remote

Holster
1. Mount the holster approximately 40”- 48” from the floor, or determine the best location as preferred
by end user, Fig.43.
2. Route the cable from the liftgate up through the inside corner post or between the wall extrusions of
the truck. Use the wire clamp to secure the incoming cable, Fig.44.
3. Splice the cables from the liftgate to the hand held remote with butt connectors and seal each
connection with heat shrink.
Corner Post
Secure liftgate wire

with wire clamp at
entry point
or
or Flo
Flo
l n
l ion Sil sio
Sil ns xten
xte dE
dE Be
Be
Fig.43 Fig.44
Wiring Table
Wires From
Function To
Gate/Number
Up Solenoid 5 / Red
Down Release Valve 6 / Yellow
12V (Hot) ON/OFF Switch 4 / Green
Rev. 1.2 - 49 -
4. Use a plug and socket when the vehicle is a refrigerated body. Remove the set screw to access the
wire terminals. Never store remote inside refrigerated vehicles, control will be damaged.
Set Screw
Plug
Plug to Control Wiring Table
Function Plug Remote
Up 5 5.2 / Red
Down 6 6.2 / Yellow
5 4 12V (Hot) 4 4.3 / Green
Key
6
Wiring Terminal
Rear View
Hand Held Remote

Set Screw
Socket
Socket to Pump/Motor
Pump
Function Socket Motor
Up 5 Solenoid
4 5 Down 6 Release Valve
12V (Hot) 4 On/Off Switch Hydraulic Power Unit
6 Key
Wiring Terminal
Rear View
5. Reference Sections 13.9-13.10 for wiring diagram.
Rev. 1.2 - 50 -
13.9
Important Note:
-All connectors are to be insulated and weather sealed.
Rev. 1.2
Starter - #5 Brown Raise -In-Line ATC Fuse 15 Amp at solenoid. Replace with
(Optional 2nd toggle) same amperage fuse when necessary.
Power - #4 Blue Cut ends off of toggle NOTICE: DO NOT attempt to jump in-line fuses
when it is an additional with other objects other than the specified fuse(s).
Lower - #6 Yellow/Green toggle and add piggy DO NOT increase the amperage rating of fuse.
Lower back connectors to all ends Serious harm to the liftgate will result when
standard practices are not followed.
Heat shrink all
Piggy Back connectors Toggle Switch
Starter - #5 Red Splice

PLR 20S/25S/25D/33D
Connectors
Power - #4 Green Harness
Lower - #6 Yellow
Raise
2-Button
Hand Held Remote
(Optional)
Piggy back with
Lower - #6 - Yellow/Green Lower Toggle Switch
Toggle Switch
Brown - Power ON/OFF Switch

Trailer Installation
Raise - #5 - Brown
Power - #4 - Blue
Wiring Diagram (Gravity Down)
Blue - Load
OR
Brown - Power
Brown - Power
Power
Blue - Load Blue - Load
MBB Germany Cable # 3273863 Load
Ground
Yellow/Green - Ground Yellow/Green - Ground
Spade Connectors ON/OFF Switch
with housing Truck Installation
15A Fuse
70-0312-002
Optional
Lower Valve(s)
Power
at Cylinders
Yellow/Green - Ground
Down
Torque Specifications
Starter Solenoid:
Ground M6: 1.3 ft/lbs. [1.7 Nm]
M8: 3 ft./lbs [4 Nm]
Power
Electric Motor
M8: 6.3 ft/lbs. [8.5 Nm]
Starter
Solenoid
30 Ft. x 2 ga.
Battery Cable
12V Power Supply
2 ga.Ground
Cable at *A second valve applies to a power down unit.
Enclosure See Wiring Diagram (Power Down)
PLR (Gravity Down) - Wiring Schematic

150 amp
Circuit Breaker Toggle control - Pump - Full Time Gravity Down 15939 Piuma Ave. Cerritos, CA 90703
Installation Manual
- 51 -
Important Note:
-All connectors are to be insulated and weather sealed.
13.10
ON/OFF Switch
(Trailer Application) -In-Line ATC Fuse 15 Amp at solenoid. Replace with
Rev. 1.2
same amperage fuse when necessary.
OR ON/OFF Switch NOTICE: DO NOT attempt to jump in-line fuses
(Truck Installation) (Optional 2nd toggle) with other objects other than the specified fuse(s).
Power - #4 Blue Cut ends off of toggle DO NOT increase the amperage rating of fuse.
Raise
Starter - #5 Brown when it is an additional Serious harm to the liftgate will result when
Power toggle and add piggy standard practices are not followed.
Lower - #6 Yellow/Green
Load Lower back connectors to all
Power - Blue
Power - Brown
Ground
Spade Connectors
with housing
PLR 20S/25S/25D/33D
Heat shrink all 2-Button

piggy back connectors Hand Held Remote
(Optional)
Piggy back with
Splice Toggle Switch
Connectors
Power - #4 Green
Power - Brown
Starter - #5 Red
Load - Blue
Ground - Yellow/Green
Harness
Lower - #6 Yellow Lower Valve Lower Valve
S1 S2
Main Liftgate
Toggle Control Switch
Raise
Power - #4 - Blue
Wiring Diagram (Power Down)
Lower
Ground - Lower Solenoid - Black

Lower Solenoid - Black
Lower Solenoid - Black

Ground - Lower Solenoid - Black
Raise - #5 - Brown
Lower - #6 - Yellow/Green
5 6 S1
15A Fuse
Shift Solenoid - Yellow
S5
70-0312-002
Yellow/Green - Ground
Torque Specifications
Starter Solenoid:
30 Ft. x 2 ga. Ground M6: 1.3 ft/lbs. [1.7 Nm]
Battery Cable
M8: 3 ft./lbs [4 Nm]
Power
Power Down Harness
with Diode Electric Motor
Starter M8: 6.3 ft/lbs. [8.5 Nm]
Solenoid
Shift
Shift Solenoid - Yellow
Valve
150 amp
Circuit Breaker
12V Power Supply
2 ga.Ground
Cable at
Enclosure
PLR (Power Down) - Wiring Schematic
Toggle control - Pump - Full Time Power Down

15939 Piuma Ave. Cerritos, CA 90703
Installation Manual
- 52 -
14 Hydraulic Schematic (Gravity Down)
 Insure that all hydraulic hoses are secured and away from heat sources, sharp corners/edges,
and abrasion from moving components during the operation of the liftgate and vehicle.
S1 & S2 - Release Valve for Lowering

R1 & R2 - Flow Restrictor for limiting lower speed.
Raise = M
Lower = S1+S2
Dual Cylinder Option
S1 S2
R1 R2
Lift Cylinder Lift Cylinder
Pump Unit "A"
Pump Unit M-3441-0104
Pilot to Close
Check Valve
M Pump
Motor Relief Valve PSI:
Dual Cylinder: 2200
Single Cylinder: 2850
Port Breather
Filter
Reservoir Tank
PLR Gravity Down

USA Hydraulic Schematic
Discontinued on liftgate S/N: PT-10598 15939 Piuma Ave. Cerritos, CA 90703
Rev. 1.2 - 53 -
14.1 Hydraulic Schematic (Power Down)
S1 & S2 - Release Valve for Lowering

R1 & R2 - Flow Restrictor for limiting lower speed.
S5 - Shift Valve is activated upon LOWER function only.
Pilot to close check valve is NOT used on Power Down.
Raise = M
Power Down = M + S1&2 + S5
Dual Cylinder Option
S1 S2
R1 R2
Lift Cylinder Lift Cylinder
Pump Unit "B" "A"
Pump Unit M-3441-0104

S5 Shift Valve
2 Position
4 way Valve
Pilot to Close
Check Valve
M Pump
Relief Valve PSI:
Motor
Dual Cylinder: 2200
Single Cylinder: 2850
Port Breather
Filter
Reservoir Tank
PLR Power Down

USA Hydraulic Schematic
MBB Toggle Control; Full time Power Down ONLY Discontinued on liftgate S/N: PT-10598 15939 Piuma Ave. Cerritos, CA 90703
Rev. 1.2 - 54 -
15 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. Please make sure to place the maximum capacity decal (D) on driver and curb
side of the vehicle.
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-ILR-ILFS 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-UD Toggle Switch Decal (located on post for Trucks)
Or (located on strut brace for flatbeds)
J 1 ATG-WNG Warning: Use handle to open (must be located
underneath handle (main section of platform))
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. 1.2 - 55 -
Decal - A Decal - B Decal - C
Decal - E
Decal - F
Decal - D Decal - G
Decal - H Decal – I
Decal – J
G
D Driver Side
F
G
I
E
F
Curb Side
A
B
I
J
Rev. 1.2 - 56 -
16 Lubrication
1. Lower the platform to the ground.
2. Remove red protector caps from each zerk. Lubricate, grease, and oil per diagram below.
3. Cycle platform up and down several times. Lubricate and grease all points again.
4. Wipe any excess grease and cap all zerks.
4 Zerks:
- 1 Lift arm IN Open enclosure to
- 1 Parallel arm
check and refill oil.
- 2 Cylinder
OUT
4 Zerks:
- 1 Lift arm
- 1 Parallel arm
- 1 Shackle
4 Zerks:
- 1 Cylinder
- 1 Lift arm
- 1 Parallel arm
- 2 Cylinder
IN 4 Zerks:
- 1 Lift arm
- 1 Parallel arm
-Platform Hinges
- 1 Shackle
-Cart Stops (if installed)
- 1 Cylinder
PLR Dual Cylinder
Rev. 1.2 - 57 -
2 Zerks:
- 1 Lift arm IN Open enclosure to
- 1 Parallel arm check and refill oil.
3 Zerks: OUT
- 1 Lift arm
- 1 Parallel arm
- 1 Shackle
2 Zerks:
- 1 Lift arm
- 1 Parallel arm
3 Zerks:
- 3 Cylinder
IN
3 Zerks:
-Platform Hinges - 1 Lift arm
-Cart Stops (if installed) - 1 Parallel arm
- 1 Shackle
PLR Single Cylinder
Grease: Location of Grease Zerks.
IN
OUT
Oil: Oil level in the power pack tank (see marking inside of power pack reservoir).
IN Lubricate: Platform hinges, Slide Rails and optional Cart Stops.
Rev. 1.2 - 58 -
17 Final Inspection (Check Off Sheet)
Liftgate failure or malfunction could result in property damage, personal injury or death if you fail to check
each of the following items listed. DO NOT USE the liftgate if any of the following points are NOT verified and
checked.
Installation is NOT complete and all WARRANTIES are VOID if you have not checked and verified all items
listed on this inspection sheet. Inspection sheet is to be filled out at the facility where liftgate was installed
and MUST be sent to Palfinger Liftgates for warranty activation.
Structural Inspection
All welds are 100% complete per this manual.
All nuts, bolts, mounting hardware, pins, chain anchors are tight.
All mounting dimensions are correct and liftgate is centered and squared per this manual.
Hydraulic Inspection
Pump reservoir is filled to 1“ from top of reservoir when cylinders are completly compressed (platform is
resting on the ground).
Hydraulic components and connections do not leak.
(Should be checked after unit is hydraulically locked for five (5) minutes.)
All hydraulic lines are secured with cable ties, hoses clamps, or other fasteners. No hoses or components rub on
the frame, platform, or any other components while unit is in operation or in storage. No hoses are kinked or bent.
Electrical Inspection
Battery cable(s) attached and clamped tight and dielectric grease is used to seal all connections.
All electrical lines are secured with cable ties, hoses clamps, or other fasteners and are properly protected.
Circuit Breakers installed and wired per instructions.
Measure battery voltages: Flooded Batteries = 12.6V; AGM Batteries = 12.8V
Lights wired properly and operate per DOT, State, and Federal requirements.
Operational Inspection
All decals are in place and legible per instructions.
All pivot points are lubricated per instructions, and zerk fittings have been capped.
Up stops are in place. Wheel is set for proper opening when lowering.
Coil springs have been adjusted at the platform for proper folding and unfolding tension.
 Snubber pads are tight against platform.
Safety chain has been hooked to platform (Section 12.3).
Platform travels up and down smoothly and freely, without any hesitation, interference, or unusual noises.
Platform is flush with the bed extension, tip is pitched according to Pitch Table (pg. 25) when raised completely.
Platform tip rests on the ground when lowered completely.
Platform raises and lowers properly and at correct speed (2 to 4 inches per second).
Gate is painted, body is clean around gate. Chrome cylinder shafts are not painted. Rubber & plastic caps are
in place.
The liftgate serial number and model number are documented on the inside of the front cover of the Owners
Manual (pg.4), as well as the installation manual in the space provided (pg.4).
Owners Manual is in the vehicle's glove box.
Supervisor has demonstrated the instructions in the Owners Manual to the customer/driver upon delivery.
Inspection Information (Please Print):

Name:____________________________________________Signature:________________________
Completed by: ______________________________________________________________________
Title: _____________________________________________Date:____________________________
Liftgate Model:_______________________ Liftgate Serial Number:____________________________
Rev. 1.2 - 59 -
Rev. 1.2 - 60 -

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INSTALLATION MANUAL

& CHECK OFF SHEET

PLR 20S/25S/25D/33D Installation Manual

Information in this document is subject to change without notice.

If you received this product with damaged or missing parts,

Palfinger Liftgates, LLC.

Palfinger Liftgates, LLC.

Rev. 1.2 -2-

Rev. 1.2 -3-

13.7 Liftgate Shut-Off Switch ................................................................................................ 47

Vehicle Year Make & Model:

Liftgate Serial Number:

Liftgate Model Number:

Rev. 1.2 -4-

Rev. 1.2 -5-

 Always be aware of your surroundings.

Rev. 1.2 -6-

 All welding should be performed by qualified personnel per AWS standards.

 Refer to Owner’s Manual for Operation and maintenance information.

Rev. 1.2 -7-

3) Call your Palfinger Liftgates Authorized Service Center for assistance.

Rev. 1.2 -8-

4.1 Boxed Items

Owner's Manual Installation Manual Decal Kit

For Trucks For Trailers

Rev. 1.2 -9-

5.1 PLR S-Model Liftgate (Single Cylinder)

PLR Liftgate Optional Configurations

Standard Bumper DOT Bumper Hitch Bumper

Fig.3 Fig.4 Fig.5

5.3 Important Dimensions

Body Long Rail

Trailer Chassis Dimension Sheet

E = Tire to end of vehicle body:......................................................................................................................................________

Rear View of Trailer Z

Walk Ramp (if applicable)

Truck Chassis Dimension Sheet

Side View of Truck

800mm [31.50] Liftarm

Vehicle Platform Sizes

900mm [35.40] Liftarm

Vehicle Platform Sizes

8 Chassis and Body Preparation - 800mm [31.50“] Liftarm

Bed Height "A"

Mounting Dimension Table

G Dim = Bed Height – F Dim. – Mount Frame Height

9 Chassis and Body Preparation - 900mm [35.40“] Liftarm

Bed Height "A"

Mounting Dimension Table

G Dim = Bed Height – F Dim. – Mount Frame Height

10.1 Sill Cutouts

Rear View of Trailer

Sill Height 4.25"

Reinforce all sill cutouts with flatbar, Fig.8

11.1 Bed Extension (Weld-On)

Body Long Rail

Body Long Rail

Body Long Rail

90° 3" Channels