ILF 44/55 INSTALLATION MANUAL & CHECK-OFF SHEET. ECN-M0253 Rev. 1.4, Date Part #

Transcription

1 ILF 44/55 INSTALLATION MANUAL & CHECK-OFF SHEET ECN-M0253 Rev. 1.4, Date Part # PALFINGER Liftgates, LLC Piuma Ave., Cerritos, CA Tel (888) Fax (562) PALFINGER Liftgates, LLC. 572 Whitehead Road, Trenton, NJ Tel (609) Fax (609) Visit our website at for up to date information and notifications If you received this product with damaged or missing parts, Please contact PALFINGER Liftgates at (888)

2 TABLE OF CONTENT TABLE OF CONTENT TABLE OF CONTENT Important Notes: Dimension Sheet Installation Dimensions ILF 44 and ILF Chassis and Body Preparation for special applications Bed Extension & Dock Bumper Installation Gate and Platform Installation Sill Preparation Installation with platform clamped Installation without platform attached Adjustment of the tilt cylinder Setting and Operation of B-15 Sensor Setting and Operation of B-13 Sensor Platform Installation Final Welding Electrical Installation Main Power Connections On-off switch installation (Truck / In-Cab) On-off Switch Trailer application Remote Hand Control Installation Foot Control installation Wiring Diagram Lubrication and Final Inspection Hydraulic Schematic Check Off Sheet Revision

3 TABLE OF CONTENT Recommended Tools For Installation Metric Wrench Set Basic Screwdrivers Pliers Wire Crimp Pliers Test Light Snap Ring Pliers Hammer Metric Allen Set 1.5mm-10mm ½ Impact & Sockets Sm. Metric Socket Set Assorted Drill Bits Floor Jack or Equiv. Sm. To Med. Bottle Jack Forklift or O/H Crane Hand Held Grinder Paint Gun Pry Bar 3/8 Drill Motor Heat Gun or Equiv. Min. 250 Amp Welder Cutting Torch or Equiv. Revision

4 1 Important Notes: 1 Important Notes: 1. Read Manual completely before beginning any work 2. Refer to your truck manufacture s instructions before adding any auxiliary equipment. 3. Pay Special attention to items marked with this symbol 4. All welding should be performed by qualified personnel per AWS standards 5. Always Ground closest to your welding point to prevent arcing through moving parts 6. Contact PALFINGER Liftgates for Special Installations not covered in this Installation Manual 7. Do Not Paint Cylinder Shafts or Nylon Rollers (Use Non-Chlorinated Brake Cleaner to remove over spray) 8. Verify Pin Bolts are tight 9. Grease all pivot points 10. Verify ALL Decals properly placed (Contact PALFINGER Liftgates to replace any missing decals) 11. Final Check Off Sheet at rear of this Manual MUST be filled out and kept in your records for future reference. 12. Refer to Owner s Manual for Troubleshooting & Repairs. Important Dimensions: (Refer to line drawing on following pages) BED HEIGHT [H] Bed Height Ranges: Max=Unloaded / Min=Loaded Truck Measure from top of body floor to ground. Vehicle must be on flat level ground when measured. MOUNT TUBE HEIGHT [F] Measure from TOP of Mount Tube to TOP of body floor MOUNT TUBE [K] Measure from rear of body to forward edge of Mount Plate. REAR SILL CUT OUT [S] Refer to H, K &S Charts and Cut Out diagrams on following pages GROUND CLEARANCE Measure from BOTTOM of Mount Tube to ground Revision

5 1 Important Notes: Mounting Notes: Read and clearly understand manual BEFORE beginning ANY work Important!!! The basic rule of PALFINGER Liftgates s ILF installation is to lift mount frame to achieve MAXIMUM ground clearance WITHOUT exceeding Min F dimension. Refer to mounting tables and determine the proper [S] dimension. If the floor sill is greater than what s allowed, the floor sill has to be notched and capped to achieve original strength. Bend flat stock and weld 100% around the notch. Warning Minimum bed height dimensions are ALWAYS MAX LOADED. Floor Height Ranges: Max=Unloaded Truck/Min=Loaded Installing a gate at or close to minimum bed height normally results in a gate that will NOT open and close from stored position if the minimum floor height is exceeded when truck is loaded. Call tech support before starting the installation if you have any questions or concerns on mounting dimensions Revision

6 2 MOUNT DIMENSIONS 2 Dimension Sheet Revision

7 2 MOUNT DIMENSIONS Revision

8 2 MOUNT DIMENSIONS 2.1 Installation Dimensions ILF 44 and ILF 55 IMPORTANT: Always use the smallest F-dim possible for best ground clearance (Don t exceed max. ground clearance!) Minimum bed height is when truck/trailer is loaded to MAX GVW Min of 8" over lap F- DIMENSION (inches) Mounting Table K DIMENSION ( inches) K-Dimension Min 26" Max 29" F-Dimension Min 25" Max 28" Bedheight Min 50" Max 55.5" 21.5" Ground Clearance Min17" Max 19.5" 102" 67" 48" Figure 2.1: ILF Installation table Revision

9 3 Chassis and Body Preparation 3 Chassis and Body Preparation for special applications The ILF liftgate will require different mounting space requirements depending on floor heights. 1. Determine the correct frame cut out according to your specific bed height (refer to Figure 2.1). With long overhangs it is even more important to maintain min F = Max ground clearance. 2. Trim rear of truck frame per Liftgate mounting table. 3.1 Bed Extension & Dock Bumper Installation Bed Extension Must Be Flush With Floor at Back & Front Edge Channel or Equiv. Tack or clamp channel to hold in place Interlift 16" Bumpers might need notching in some cases 16" 1" x sill depth 3/16" Tack Weld Or ClampTo Rear Sill 3" Channel 12" 3/16" welds for bed extension Do NOT weld along vertical posts on van install. 3/16" 3/16" Channels Shipped W/ Sq. Ends (Customer Must Miter Per Application) 4" Channel standard to clear shackles Figure 3.1: Bed Extension install Figure 3.2: Dock Bumper install 1. Tack weld channels or angle (2) to rear sill (not supplied) 2. Center bed extension, flush with floor. (Figure 3.1) Clamp or tack weld to channels or angle 3. Verify bed extension is centered on body and flush 4. Weld as shown in Figure 3.3 -> 3/16 x 4 welds on approximately 10 centers alternate top and bottom welds No weld areas Weld the 6 vertical braces 100% under the bed extension on unit Do not weld across the corner posts 6 ea. Figure 3.3:Bed extension weld areas 5. Install dock bumpers (available from PALFINGER Liftgates as an option) 6. If installing PALFINGER Liftgates dock bumpers refer to Figure 3.1 Revision

10 4 Gate and Platform Installation 4 Gate and Platform Installation 4.1 Sill Preparation 1. Notch rear sill if necessary per Mount Table for your particular model 2. Box in notch with flat bar to maintain sill strength. Refer to mounting tables and determine the proper [S] dimension. If the sill is greater than what s allowed the sill has to be notched and capped to achieve original strength. Bend flat stock and weld 100% around the notch. 3. Note: Refer to 3.1 before proceeding 4.2 Installation with platform clamped 1. Install Platform to Liftarm using short pins 2. Support Tilt Cylinders with rope or wire to avoid dragging 3. Support Platform with forklift, overhead crane or similar device 4. Support Mount Tube with rolling floor jack or similar device 5. Slide Platform/Mount Tube Assy in under the vehicle frame 6. Set Platform so it is level and flush with body floor 7. Secure Platform to body using 3 Channel or equivalent using clamps or Tack welds being sure to maintain level position to body floor Warning: Never work or place yourself under unsupported Platform 8. Place the mount tube in the predetermined position, keeping the given maximums and minimums in mind. Use floor jack or a similar device to position the mount tube. Make sure that you place the tube at a 90-degree angle to the truck bed. 3" channel clamped or tack welded in place to platform and body After securing platform swing Mount Frame to proper mount height Warning: Never work under unsupported platform. Figure 4.1:Platform install without fixture Revision

11 4 Gate and Platform Installation 4.3 Installation without platform attached The mount tube should be placed as high as possible to achieve better ground clearance, keep in mind that this also directly relates to the mount tube clearance. Make sure that you stay within the maximums and minimums given in the mounting tables. 1. Install the bed extension first. Locate and mark out the center of the rear body or bed sill. 2. Slide mount tube in under the truck frame and attach the lift arm to the holes in the bed extension. At this point you should place the mount tube in the predetermined position, keeping the given maximums and minimums in mind. You can use a forklift, a floor jack or a similar device to position the mount tube. Make sure that you place the tube at a 90-degree angle to the truck bed. (fig 4:3) Be certain to pull out power tray before welding. 3. The reservoir is made of plastic and you will burn it while welding. To pull out tray, just simply remove the bolt on the curbside and detach the ground strap and control power connector for the tray. Pull on tray until the hoses are stretched and the tank is further out than the point of welding. Verify hoses or cables are not touching inside of tube wall. Before any welding is started, check that liftgate is balanced and not binding, you should have equal pressure on each lift-arm pin. This is very important to make platform align with truck sill. Align Lift arm with Bed Extension holes Liftarm Figure 4.2: Mount frame alignment with bed extension holes Revision

12 4 Gate and Platform Installation 4. With the mount tube held in place, position the mount plates over tube and against truck frame. Position them with angle forward and clamp them to truck frame. 5. Tack weld mount plates to mount tube with a minimum three one inch welds and three one inch welds to the truck frame. Make sure to ground on the frame and not on the platform. Before finishing up all welding we recommend doing the electrical installation and platform installation to make sure that everything aligns like it should. Use a min of 8" overlap between mount plates and truck frame Weld 100% with 1/4" weld against the frame and both sides of the plates against the mount frame Install Lower Gusset Supplied ON 5500 LB Units ONLY Before running the unit through its cycle, make sure that the In-Cab Switch is in the ON position (Lights are on) Before running the unit through its cycle, make sure that the solenoids on the lift cylinders are not hitting the mount plates. Revision

13 4 Gate and Platform Installation 4.4 Adjustment of the tilt cylinder Tilt cylinder can only be operated, when Sensor B-13 is indicating Liftarm on Ground and Sensor B-15 is indicating Platform pulled out. See next chapter for details. Adjust Tilt Cylinders at Clevis, so platform can be easily un-folded and stored. Loosen Lock Nut on piston, turn piston using flat areas. Clock wise to shorten. Counter Clock wise to extend. **Secure piston rod with lock nut when finished Adjust Bolts to level platform: Secure bolt with lock nut after adjustment Wrench Sizes For Tilt Cylinder Adjustments Gate Model Nut Piston ILF 33 50MM 36MM ILF MM 42MM When installing the tilt cylinder into the platform, extend the tilting cylinder by pressing the switch for opening and closing until it is possible to pin the cylinder to the platform. For this purpose, hold the inclination sensor B-15 with the cable down. Revision

14 4 Gate and Platform Installation Round side of Tilt Cyl. Clevis MUST face down toward ground (Detail Y) Pin only one cylinder at a time to the platform DETAIL Y Lock nut to be tightened after clevis adjusted If you have not finished the welding, carefully run lift to see if it is properly aligned with the floor sill. Make sure to tighten the tilt piston rod lock nuts when you are finished. Never power the lift hard against anything if you have not finished welding. 4.5 Setting and Operation of B-15 Sensor 1. Mount the inclination sensor B-15 to the right-hand side of the platform as shown below. Make sure to loop wire around to give it enough slack in normal operation and route clear of any pinch points. 2. Loosen (2) 5mmx50mm Allen Head sensor mount screws and rotate slightly for readjustment. Retighten screws Platform Profile Warning Light/Foot Control (option) Harness Wire Ties Cable Cover/Clamp B-15 Sensor Liftarm Warning Light/Foot Control (option) MUST have all connectors inserted into platform profile after connections are made. Loop per drawing to allow for proper movement TIRE 4.6 Setting and Operation of B-13 Sensor 1. Raise platform approx off ground and verify platform is level (tilt if necessary) 2. Loosen lock bolt and set sensor level with platform/ground (verify colored side of sensor is out) 3. Lower platform to ground. When properly set, platform should remain level for approx. 2 seconds then tilt tip to ground. 4. Cycle Platform from bed height to ground several times to verify proper operation. Tilt sensor slightly forward or back to achieve proper Auto-Tilt action. Revision

15 4 Gate and Platform Installation Lock Tab B-13 Sensor Lift Arm Lift Cylinder Tilt Cylinder At NO time should the platform tilt tip towards ground while lowering. Platform should ONLY tilt AFTER Lift Arms/Nylon Rollers contact ground. 1. After sensor is properly set, tighten lock bolt to 43 in.lbs/3.5 ft.lbs 2. Cycle platform several times to check operation after tightening. 3. Fold down Lock Tab tightly onto Lift Arm Never over torque B-13 lock bolt. Verify colored resin side of sensor is out (facing away from arm) B-13 Sensor horizontal in this position B-15 12"-15" Under torqued B-13 lock bolt may allow sensor to shift during normal gate operation. 4.7 Platform Installation 1. Support platform horizontally with forklift, overhead crane or similar equipment 2. Install platform onto lift arm using small pins 3. Tighten 4. Connect cables verifying that connectors are fully seated Your Connectors for Warning lights, Sensors and switches from platform and gate should be marked with colored tape from the factory for easy identification and placement. Notify PALFINGER Liftgates, LLC if not. 5. Push cable and connectors into platform so that large portion of cable is clamped in cover and all connectors inside platform. Revision

16 5 Electrical Installation 4.8 Final Welding Make sure to have power pack pulled out when welding the tube and hoses and cables are away from walls. Make sure to ground to the frame and not to the platform to avoid sparking and arching on the cylinder. Protect all wires from dropping slag or splatter when welding mount plates. 1. Verify the platform is in the correct position in relation to truck sill. 2. Weld tube and mount plates (and lower gusset on 5500 lb models) with a 1/4 fillet weld 100% of the area around mount tube and around frame on both sides of plates. The plates must have a minimum of 8 of overlap on the frame. PALFINGER Liftgates recommends adding ¼ flat bar or plate to the top of mount plates if needed to tie Liftgate mount plates to body stringer Mount Plate Chassis/Trailer Frame 8" Min 100% 1/4" Fillet Weld Mount Tube 100% 1/4" Fillet Weld on both sides of Mount Plate Revision

17 5 Electrical Installation 4.9 Decal Placement and Inspection For operator safety, all decals appearing in Decal Kit must be in a conspicuous place on control side of liftgate. This is typically a combination of decals on the liftgate and truck or trailer body. Please make sure to place the maximum capacity decal (C) on driver and curb side. (A) 1 ATG-URGWA - Urgent warning: Elevating gate instructions (C) 1 ATG-BKR - Circuit Breaker Reset (must be located at the circuit breaker) (D) 2 ATG-XXXX - Max. Capacity (please check the serial number plate to find out your specific capacity) (E) 1 ATG-RESET - Circuit Breaker Protection (F) 2 ATG-WLH - Warning: liftgate can crush (G) 2 ATG-CTN - Caution: Always stand clear of platform area (H) 1 ATG-CAB - Liftgate Shut-Off (Place Decal next to the On-Off Switch in the Cab) (K) 1 ATG-WNG - Warning: Use handle to open (must be located underneath handle (main section)) (L) 1 ATG-FT- Notice for Foot Control (if applicable) Decal - A Decal - E Decal - C Decal - D Decal - H Decal - F Decal - G Decal - L Decal - K Revision

18 5 Electrical Installation (A) 1 ATG-URGWA - Urgent warning: Elevating gate instructions (B) 1 ATG-ILR-ILFS - Operational Instructions Decal G (C) 1 ATG-BKR - Circuit Breaker Reset (must be located at the circuit breaker) Decal D (D) 2 ATG-XXXX - Max. Capacity (please check the serial number plate to fi Decal L Decal F (E) 1 ATG-RESET - Circuit Breaker Protection (F) 2 ATG-WLH - Warning: liftgate can crush Decal E (G) 2 ATG-CTN - Caution: Always stand clear of platform area (H) 1 ATG-CAB - Liftgate Shut-Off (Place Decal next to the On-Off Switch in the Cab) (J) 1 ATG-UD - Toggle Decal (K) 1 ATG-WNG - Warning: Use handle to open (must be located underneath handle (main section)) Decal - A Decal - B Decal - C Decal K Decal A Figure 1: Decal Placement Guideline Revision

19 5 Electrical Installation 5 Electrical Installation When performing electrical installation, please be certain to install and secure everything in a way where it is not subject to damage from moving parts, sharp edges, exhaust systems, etc. Never exceed rating of existing fuses located at the battery, control board and the pump and motor 5.1 Main Power Connections 1. Install the 2 Ga. battery cable securely from mount frame to battery. 2. Secure the cable every 12 inches. 3. Heat shrink lug connection to cable. 4. Assure all connections are tight and securely fastened. Liftgate Mount Frame Wires marked #2 ; #4 go to hot, #1 and gr/yl go to ground In-Line Control Power 4-Wire Cable Fuse on #2 and #27 Truck Application-Always wire to truck battery Trailer Application-wire to aux. battery Main Batteries Circuit Breaker To Ignition Switch Ground Battery Isolator (if applicable) Aux. Batteries (if applicable) Ga. Liftgate Power Cable Ground Cable Ground - + (Third Battery Shown for 6600 # or heavy applications Only) Ground - + Circuit Breaker Main Disconnect (if applicable) Circuit breaker MUST be fastened securely FOLLOW DOTTED LINE IF ISOLATOR OR AUXILLIARY BATTERIES INSTALLED! Revision

20 5 Electrical Installation Never secure cable in a way where it can make contact with other wiring, brake fuel or airlines etc or get pinched against other objects. Breaker Installation (Fig. 5.1) 1. Mount circuit breaker securely in battery box 2. Connect liftgate 2Ga. cable to open stud on circuit breaker 3. Connect 2Ga. jumper from forward most stud on breaker to positive battery post RESET 150 AMP Resetable Breaker Connect 4 Wire Harness directly to Truck Battery 1. Determine location for fixed control box; locate it in a way that the operator can view the platform and surrounding areas while operating the liftgate. Also, locate in a way where the lid does not extend out side the van body when open. 2. Lead the 4-wire cab switch cable together with the battery cable and the 4 wire harness for the control power to the batteries along the sub-wood. Secure the cable every 12 inches against the sub-wood with cable staples. Run the cab switch cable only into the cab 5.2 On-off switch installation (Truck / In-Cab) Install the shut-off switch inside the cab. Locate it where it can conveniently be seen and reached from the drivers seat as well as from the ground Revision

21 5 Electrical Installation Do Not use In-Cab Switch for Trailer Applications. Your Liftgate should be outfitted with a Trailer Cut Off Switch and Wiring in Control Box from the factory. If not, refer to Cut Off Switch for Trailer Application 5.3. Place cab shut off in view of the driver and within reach from the ground Recommended Cable Routing for Trucks Route Cables to OUTSIDE of U-Bolts 4-Wire Control Cable Battery Cable Body Stringer Cable Staples 2 Wire Control Box Power Cable Sub Wood Truck Frame For trailer installation refer to trailer manufacturers recommended routing In-Cab Cut-Off Switch (For Truck Use Only) "Off" Symbol Blue (#4) Blue (BS3) Red (#2) Green/Yellow (-) White (#1) In-Cab Switch Color and Number Coding Cable wires are marked: Cab Shut off switch code 1 = Hot Lead To Red L.E.D. Lights - WHITE (-) = Ground To L.E.D. Lights - GREEN YELLOW 2 = 12 Volt Power From Batteries - RED 4 = Control Power To Liftgate - BLUE 1. Install the supplied breaker to the positive terminal of the battery using brass lug. Install the 2 ga. cable from the power pack to circuit breaker. 2. Install the 4 wire harness for the control power to the batteries. Attach 2 and 4 to positive with an inline 20 amp fuse at the battery, wire 1 and green and yellow to negative on battery. Revision

22 5 Electrical Installation 5.3 On-off Switch Trailer application On a trailer installation the control port J11 has to be connected with a on off toggle switch connecting 2 and 4 on port J11 together. On-Off-Switch Unplug exsiting J11 connector from board Install 2 Position Toggle Switch in Control Box Face Run leads from Toggle Switch to #2 & #4 on Circuit Board Use Tie Straps to hold unused J11 Connector in safe location The Circuit Board is located behind the rubber cover on the curb side of the 7 x 7 mount tube. Revision

23 5 Electrical Installation Inspect and test all electrical connections, wiring and the different functions to make sure that the electrical installation is complete. 5.4 Remote Hand Control Installation Hand Controls are NOT weatherproof and are to be stored inside body in holster or in weatherproof box (PALFINGER Liftgates option). For Refer, Flatbed installations or stored in cab solutions we recommend plug & socket option. Hand Control Holster Mount Holster inside body on curb side at rear Mount approx. 40"-48" from floor (end user needs may very) BUTTON NO. 1 UP BUTTON NO. 2 DOWN Connect all wires together according to cable ID s. Use heat-shrink to seal the connection. 3 Button Hand Control Function From H/C / Color From Gate / Number Up / Yellow #4 Down / Brown #3 12V Hot / Red 4 Gn/Ye Tilt-Up / White #1 Tilt-Down / Green #2 Existing Wire on Gate: 1. Find hot wire & touch hot wire to other wires. Revision

24 5 Electrical Installation 2. Note function and match to above. Optional Plug and Socket application 2 Button Hand Control #3 #2 Green/Yellow #1 Female Receptical (Looking at Front) Figure 5.1: Plug& Socket wiring for Hand Control #4 5.5 Foot Control installation After installing the platform connect the wiring harness from the platform to the connections at the liftarm. Each foot switch has a hot (wire #4) on plug J3. Switch (1) connects in addition to port (5) on J3, switch (2) connects to port (6) on J3. Make sure that connections are wire tied together and pushed inside the platform. DOWN: Step on switch 1 and hold wait between one and three seconds before you step on switch 2. UP: Step on switch 2 and hold wait between one and three seconds before you step on switch 1. The platform will tilt up to preset position before raising. IF BOTH SWITCHES ARE NOT ACTIVATED BETWEEN ONE TO THREE SECONDS, START OVER. Revision

25 5 Electrical Installation 5.6 Wiring Diagram * Good voltage is the most important first step in troubleshooting the litgate. * Test voltage at the J11connection between wire 4 and ground (min. 10 V). * When testing for electricity on the individual solenoid plug at the cylinder, always test voltage between the two prongs on the plug itself.(min. 7 V) * After troubleshooting, carefully close the rubber cap and secure it with the plastic strap. * When testing the voltage on different locations, always ground on plug J1. Tilt - Up bypass -- J11 #4 min. 8.5 V 150 HACKBARTH CIRCUIT BOARD # 2 BLACK # 4 BLACK (+) # 1 BLACK GREEN / YELLOW (-) ILF 44/55 KPLUS LI : Lift Up LO : Lower Down OP : Open Gate CL : Close Gate Legend : gn : green bl : blue br : brown wt : white ye : yellow sw / bk : black gy : green-yellow LIFT LOWER CLOSE OPEN OPTIONAL WIRELESS HANDCONTROL Figure 5.2: Electrical scematic Revision

26 5 Electrical Installation B13 LIFT ARM B15 PLATFORM GROUND for PC BOARD (green/yellow and black # 1) WARNING LIGHTS FOOT CONTROL CAB CUT OFF SWITCH CONTROL BOX POSITIVE for PC BOARD (black #2 to 2 and black # 4 to 27) POWER PACK HAND REMOTE CYLINDERS LIFT 15 (2 ea) TILT 14 (2ea) AUX port CIRCUIT BOARD K+ Figure 5.3: Electrical wieing overwiev Revision

27 6 Lubrication and Final InspectionL 6 Lubrication and Final Inspection 1. Open platform and lift gate to bed level 2. Remove red caps, apply grease until grease begins to flow from bushing ends (12 points) 3. Lower platform to ground and repeat 4. Cycle platform up and down, fold in and out several times and grease again (Fig. 6.1) 5. Wipe excess grease from joints and replace ALL red caps 6. Check ALL pin bolts for proper torque of 14 ft-lbs 7. Paint all welded areas and area that have been scratched during installation Note:- Do not paint chrome hydraulic shafts 8. Remove any overspray from cylinder shafts 9. Check for any wires or hoses that may rub during operation. 10. Re-route and/or tie up wires and hoses as necessary 11. Lower platform completely to ground to check oil 12. Slide out pump/motor on curb side and check oil level 13. Check Plugs on PC Board. Push tight and reinstall clamp on cover 14. Install all operation and safety decals (Error! Reference source not found.) TIRE 4 6 TIRE 5 Figure 6.1: Lubrication Points (opposite direction on curb side ) Revision

28 6 Lubrication and Final InspectionL 6.1 Hydraulic Schematic Functions: S1 and S2 = Release Valve for lowering function S3 and S4 = Release Valve for tilt down function R1 and R2 = Flow Restrictor located inside hose adaptor on lift cylinder R3 and R4 = Flow Restrictor located inside hose adaptor on tilt cylinder S5 = Shift Valve is activated on tilt up and lowering function R5 = Restrictor Valve located in power pack Flow Divider is activated, when fluid is going back into the power pack If Flow Divider is loose or hanging up the fluid is circulated back in to tank Shift Valve S5 Restrictor Valve R5 Flow Divider Functions: Lift: M Lower: S1+S2+S5 Tilt Up: M+S5 Tilt Down: S3+S4 Horiz. Open: M+S3+S4 Pressure Relief 2850 PSI 200 bar Revision

29 7 Check Off Sheet 7 Check Off Sheet SECURED 2. No Rubbing On Platform 6. Platform hits rear sill even 3. Up-Down Clear at the same time 4. Storing Platform Clear 7. Titl cylinder clevis adjusted properly HYD. OIL 1. None At Hoses 8. On No Auto Paint Tilt on Knuckle cylinder LEAKS 2. None Power Pack shafts 3. Cylinders FINAL 1. Platform Touches Ground WELDS 1. Full Welds Mount Plates INSPECTION 2. Lights Working On Chassis 2. Ground Off / Clean 3. Lic. Plate Bolts & Lights 3. Frame Capped Off 4. Decals Installed 5. Rubber & Plastic Caps In Place PUMP 1. Check Fluid With Platform On Ground 6. Gate Painted Completely & MOTOR 2. Connections Tight With Heat Shrink 7. Body Clean Around Gate 3. Power Cable Tight 8. Pin Greased - 12 Places 4. Ground Cable Tight 9. Cylinders Clean 5. Breather Installed 6. Cables Tied Off OPTIONS 1. All Options On Gate 7. Fuses Tight 2. Circuit Breaker Tight 8. Clamp on rubber cover & Decal In Place 3. Cart Stops Working PINS 1. Grease Zerks In Place 2. Red Grease Caps On Zerks CHECKED BY 3. Bolts Tight On Pins 4. Ground Rollers On DATE (only 44 and 55) Note: This must be filled out and kept for your records. A copy of this sheet must be presented to PALFINGER Liftgates for any warranty compensation Revision