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OCT 08, 2025

How to Install a Palfinger ILT Folding Liftgate: Complete Installation Walkthrough

Installing a Palfinger ILT liftgate correctly is essential for ensuring safe operation, reliable performance, and maintaining warranty coverage. Incorrect installation can lead to mechanical failures, electrical faults, or unsafe load handling. This step-by-step guide walks through the verified installation process for the ILT series, based entirely on official Palfinger installation and owner’s manuals.

• Documentation Resources from Palfinger
• Introduction
• Preparation and Tools Required
• Chassis and Body Preparation
• Bed Extension Installation
• Liftgate Installation Process
• Electrical Installation
• Hydraulic Setup
• Final Inspection and Warranty Activation
• Conclusion

Documentation Resources from Palfinger

Information in this article is sourced directly from Palfinger Liftgates ILT manuals and technical guides as well as our team’s expertise. Always refer to your specific liftgate’s manuals for complete procedures and serial number, model, and year-specific details.

Reference PDFs used:

• Interlift Palfinger ILT Installation Manual, Rev. 1.15 (2016)
• Interlift Palfinger ILT WR/PD Owner’s Manual, Rev. 1.4 (2013)
• Interlift Palfinger ILT Owner’s Manual, Rev. 1.6 (2016)
• Interlift Palfinger ILT Parts Manual, Rev. 1.9 (2021)

Introduction

The Palfinger ILT tuckunder liftgate combines heavy-duty performance with user-friendly operation. Its folding platform and underbody storage design allow fleets to maximize dock loading flexibility while maintaining vehicle clearance. To ensure proper function and to activate warranty coverage, the liftgate must be installed according to Palfinger’s technical specifications. This guide provides a structured walkthrough of the installation process with citations from Palfinger’s manuals.

Preparation and Tools Required

Proper preparation helps ensure installation proceeds efficiently and safely.

Safety Equipment:

• Eye protection and hearing protection are required when cutting, welding, or grinding (Installation Manual, p. 5).
• Steel-toe safety boots and gloves are recommended.

Required Tools & Materials:

• Torque wrench, sockets, and hand tools.
• Welding equipment (if using weld-on mount plates or bed extensions).
• Hoist or forklift for handling liftgate assemblies.
• Palfinger-supplied “bagged items,” which include bolts, bushings, decals, and mounting hardware (Installation Manual, p. 7).

Careful preparation ensures both safety and efficiency, reducing rework during later steps.

Chassis and Body Preparation

Correct vehicle preparation is critical for proper mounting and liftgate alignment.

Steps:

• Confirm mounting dimensions as outlined in the installation drawings (Installation Manual, p. 13).
• Ensure minimum chassis clearance requirements are met. The “F” dimension (vertical height between chassis and ground) is especially important for platform alignment.
• Perform sill cutouts or body frame cutouts if required by the specific vehicle body type (Installation Manual, p. 15).

Proper chassis prep prevents binding and ensures the Palfinger liftgate operates smoothly once installed.

Bed Extension Installation

The bed extension provides structural support for the liftgate and ensures safe loading/unloading.

Weld-On vs. Bolt-On Methods:

• Weld-on bed extensions are recommended for heavy-duty applications.
• Bolt-on kits are available for faster installation and easier replacement (Parts Manual, p. 21).

Dock Bumper Installation:

• Palfinger offers both 21-inch and 28-inch dock bumpers in weld-on and bolt-on configurations. Extra-heavy-duty bumpers are also available for trailer applications (Parts Manual, p. 29).
• Dock bumpers must be installed flush with the bed extension to absorb impact during docking.

Choosing the correct bed extension and bumper setup ensures durability and compliance with DOT rear-impact requirements.

Liftgate Installation Process

The liftgate itself must be hoisted and secured with care to prevent misalignment.

Steps:

• Hoist and align the liftgate platform with the truck body, ensuring stability during installation (Installation Manual, p. 17).
• Set the critical “F” dimension to match Palfinger specifications for platform height alignment.
• Install mount plates using either bolt-on or weld-on kits. Palfinger supplies complete mount plate kits with bolts, bushings, and torque specifications (Parts Manual, p. 7).
• For trailer applications, install a sub-frame for additional structural support (Installation Manual, p. 18).

Correct alignment and mounting are crucial for load stability and smooth liftgate motion.

Electrical Installation

The ILT series uses an electro-hydraulic system powered by the vehicle’s battery or auxiliary battery kit.

Steps:

• Route battery cables using the supplied hardware and install a 150 AMP circuit breaker near the battery (Owner’s Manual Rev. 1.6, p. 10).
• Connect the cab-mounted shutoff switch. Trailer applications use a curbside rear switch (Owner’s Manual Rev. 1.6, p. 11).
• Install the toggle switch at the curbside of the body. An optional hand-held remote may also be connected (Owner’s Manual Rev. 1.6, p. 17).
• Ensure all wiring follows Palfinger’s supplied schematics for either gravity down or power down systems (Owner’s Manual Rev. 1.6, p. 33–34).

A properly installed electrical system ensures reliable power delivery and protects against overloads.

Hydraulic Setup

The hydraulic system controls lifting, lowering, and platform tilt.

Steps:

• Verify whether the unit is gravity down or power down, and connect hoses accordingly using Palfinger’s hydraulic schematics (Owner’s Manual Rev. 1.6, p. 35–36).
• Fill the power pack reservoir with the recommended ISO 32 hydraulic oil. Oil level should be 1–1.5 inches below the filler neck when the platform is lowered (Owner’s Manual Rev. 1.6, p. 22).
• Adjust torsion spring tension as required for proper platform folding (Parts Manual, p. 17).
• Inspect rubber snubbers and sliding wheels to ensure smooth stowing action (Parts Manual, p. 7).

Proper hydraulic setup ensures smooth lift operation and prevents premature wear.

Final Inspection and Warranty Activation

Before returning the vehicle to service, Palfinger requires a documented inspection.

Checklist:

• Test all liftgate functions under load and confirm level platform operation (Owner’s Manual Rev. 1.6, p. 25).
• Inspect all welds, bolts, and bushings for secure installation (Owner’s Manual Rev. 1.6, p. 25).
• Confirm decals are installed in visible positions, including capacity and safety labels (Owner’s Manual Rev. 1.6, p. 23).
• Complete the Palfinger installation check-off sheet to activate warranty coverage (Installation Manual, p. 21).

A complete inspection not only ensures operator safety but also protects warranty eligibility.

Conclusion

Installing a Palfinger ILT tuck under liftgate requires attention to detail across chassis preparation, mounting, electrical, and hydraulic systems. Following Palfinger’s official manuals step-by-step ensures the liftgate performs safely, extends its service life, and complies with warranty requirements.

For questions during liftgate installation, always consult Palfinger technical support or contact our team at LiftGateMe for expert assistance.