ild installation manual

INTERLIFT, INC. a member of MBB
Visit out website at www.interlift.net for up to date information and notifications
15939 Piuma Ave., Cerritos, CA 90703 Tel (888)-774-5844 Fax (562) 924-8318
If you received this product with damaged or missing parts, contact Interlift at 562-924-8318
5/31/2004 Part #: 68700
For Your Safety
This Manual follows the Guidelines set forth in ANSI Z535.4-1998 for alerting you to possible hazards and their potential severity.
This is the safety alert symbol. This manual uses this symbol to alert you to potential personal injury hazards. Obey all safety messages that follow this symbol to avoid possible injury or death.
DANGER indicates an imminently hazardous situation which, if not avoided, will result in death or serious injury.
WARNING indicates a 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 used without the safety alert symbol indicates a potentially hazardous situation which, if not avoided, may result in property damage.
ILD™ Series Installation Manual
Memo To The Installer
1. Improper installation and use of this liftgate may result in serious injury or death.
2. Make sure that you are properly trained and qualified before you install this liftgate.
3. Make sure you read and understand this manual before you install this liftgate.
Please call us if you have any questions during this installation. • USA: 888-774-5844
We are committed to: • Helping you install this liftgate safely and correctly • Providing your customer with a durable, trouble-free, long-lasting liftgate
Remember, we’re on your team! Thank you for choosing our liftgates.
Sincerely, Interlift, Inc.
1. READ AND UNDERSTAND installation instructions for installing this liftgate.
2. Failure to follow all instructions may result in severe personal injury or death.
3. Do not attempt this installation if you are not a qualified trained welding technician with appropriate training in liftgate installation.
4. Do not install truck lights if you are not properly trained in truck electrical equipment.
1. NEVER stand under or near the liftgate when the liftgate is being raised or positioned for installation.
This liftgate can crush persons, causing death or severe injuries.
2. ALWAYS disconnect the truck’s positive and negative battery cables to avoid damage to the truck's electrical system.
Follow the procedures in the Vehicle Owner Manual.
3. ALWAYS turn the Master Disconnect switch to OFF when leaving the truck unattended.
4. ALWAYS lock cab doors to prevent unauthorized use of the liftgate.
5. ALWAYS affix safety decals according to these instructions.
6. ALWAYS perform final inspection after installation.
7. ALWAYS read the Operation Manual before testing or operating this liftgate.
8. ALWAYS inspect your installation and complete the Final Inspection Checklist after finishing the installation.
9. ALWAYS follow the procedures in this Manual to install the Master Disconnect Switch and the Circuit Breaker.
10. ALWAYS install the Master Disconnect Switch and Circuit Breaker before reconnecting the truck’s battery cables.
11. NEVER install the Master Disconnect Switch and Circuit Breaker if you are not properly trained in truck electrical equipment.
1.6 Special Instructions for Flat Beds and Stake Bodies....................14
2. ATTACH THE LIFTGATE ..............................................................15
3. INSTALL PUMP BOX AND PUMP FRAME ................................18
4. HYDRAULIC HOOKUP ................................................................21
5. ELECTRICAL HOOKUP ..............................................................23
5.1 Electrical Connection to Battery Box (ILD55 & ILD66 only) ........23
5.2 Secure the Cables..........................................................................24
5.4 Install Battery Cable ......................................................................27
7. BLEEDING THE LIFTING CYLINDERS ......................................33
8. TEST THE LIFTGATE OPERATION ............................................34
9. COMPLETE THE INSTALLATION ..............................................35
9.1 Affix Warning Decals ......................................................................35
Inspection Sheet ............................................................................39
ILD Series Liftgate Description
The ILD Series liftgate is a 100% level-ride, rail-style direct vertical lift liftgate. The ILD Series is available in capacities of 3,500 - 6,600 pounds.
Rail-style liftgates have two rails mounted to the rear of your truck, either by welding or bolting. These rails, also called columns, support a platform which raises and lowers cargo.
The ILD Series liftgate come in 4 basic models • ILD35 - capacity: 3500 lbs. • ILD44 - capacity: 4400 lbs. • ILD55 - capacity: 5500 lbs. • ILD66 - capacity: 6600 lbs.
Depending on what type of ILD Series liftgate you have, it may or may not lift above the floor of your truck. Models that will lift above the truck floor will have a suffix at the end of the model number: AF. Here is an example:
ILD 35 72
IMPORTANT SAFETY FEATURES
• Pressure compensated flow control valve • Treadplate platform • Toe Guard in housing cover • Platform safety lock • Close Relief Valve • Warning decals and manuals • Three way folding aluminum ramp
THEORY OF OPERATION
The rail-type direct lift vertical liftgate is designed to lift cargo vertically from the truck bed to the ground and vice versa. A hydraulic power unit provides power to two vertical cylinders that raise and lower the platform. Activation of a control switch supplies current from a 12-volt battery to the hydraulic power unit. The hydraulic power unit in turn supplies hydraulic fluid to the hydraulic cylinders, causing them to retract. The resultant upward pull on the platform raises it.
The platform is lowered by hydraulic power. Activation of the control switch directs hydraulic fluid to extend the cylinder. The resultant downward force on the platform lowers it.
The platform opens and closes hydraulically. The platform is closed by directing hydraulic fluid from the hydraulic power unit to the lower part (shaft end) of the Hydraulic Power Open and Close Cylinder. The platform opens hydraulically by directing hydraulic fluid to the upper part of the Hydraulic Power Open and Close Cylinder.
Liftgate, Installed
Slider Wear Pads
Pump Box
1. PREPARE FOR INSTALLATION
1.1 Before You Start
1. Liftgate can crush.
2. DO NOT INSTALL this liftgate if you do not understand all procedures.
3. Improper installation of the liftgate may result in severe personal injury or death.
Call Customer Service for assistance: USA: 888-774-5844
STEP 1 Check the ILD Model type (ILD35, ILD44, ILD55, ILD66).
STEP 3 Become familiar with: • The liftgate • The components in the Electrical
Component Kit • The Safety Decal Kit
STEP 2 Read this Installation Manual.
STEP 2 Determine clearance requirements. Measure Dimensions for Bed Height
Check chart below to ensure that your gate is compatible with bed height of the vehicle.
Bed Height Chart
Platform Size Dock Loading No Dock Loading Bed Height Range Bed Height Range Min. Max. Min. Max.
60" x 80" + 16" 34" 58" 34" 58"
72" x 80" + 16" 40" 58" 34" 58"
84" x 80" + 16" 46" 58" 34" 58"
STEP 1 Ensure truck body door does not interfere with installation or operation of liftgate ILD model liftgates cannot be installed with "barn" or "swing" type doors without extensive modification. Consult Customer Service for assistance or if you are not sure your vehicle meets the requirements.
74-1/2"
15-1/4"
vehicle floor
Dimensions are same for 86" platforms (for 102" wide bodies)
STEP 3 Determine wall requirements. Truck body must be capable of supporting minimum forces shown in Side Wall Requirements. See Section 1.6 (page 14) for reinforcing example.
Side Wall Requirements
STEP 4 Determine width requirements. The ILD is offered in two different standard widths, for 102" and 96" wide bodies.
Outside Platform Liftgate Frame Liftgate ID Width
102" wide body 100" 90" 86"
96" wide body 94" 84" 80"
Outside liftgate frame
X 1900 lbs. 2400 lbs. 2950 lbs. 3500 lbs.
Y 1900 lbs. 2400 lbs. 2950 lbs. 3500 lbs.
Z 2700 lbs. 3100 lbs. 3800 lbs. 4300 lbs.
X = side wall tension Y = side wall compression Z = side wall shear
STEP 2 Make sure you have all the parts in the Electrical Component Kit • Master Disconnect – pre-installed in pump box (all models) • Circuit breaker • 2 circuit breaker mounting screws • 20 plastic nylon ties • Two #1 x 3/8" copper lugs • Two #1 x 1/4" copper lugs • 4 heat-shrink tubes • 9 frame clips
20 plastic nylon ties
9 frame clips
4 heat-shrink tubes Two circuit breaker mounting screws
STEP 1 Make sure you have all the liftgate parts (liftgate, pump box [and battery box - ILD55 & ILD66 only], control switch assembly) (See Design Detail, pg. 6). Check these parts and the liftgate assembly for shipping damage. Call Customer Service if any parts are missing or defective. USA: 800-289-1335 • Canada: 416-421-7987
ELECTRICAL COMPONENT KIT
STEP 2 Make sure you have all the parts listed below. Check these parts for shipping damage. Call Customer Service if any parts are missing or defective. USA: 888-774-5844
SAFETY DECAL KIT • Urgent Warning: Elevating Gate Instructions • 2 decals, Danger Message: Liftgate can crush • 1 decal, Warning Message: Keep people clear of liftgate while operating • 1 decal, Operating Instructions • 2 decals, Maximum Capacity
STEP 4 Put the Operation Manual in the glove box.
STEP 5 Put decals in secure place for later installation.
INSTALLATION MANUAL
OPERATION MANUAL KIT • Operation Manual • Warranty Registration Card
Operating Instructions Read operating instructions before using liftgate.
Opening platform from stored position 1. Turn on power to liftgate by turning the master disconnect switch,
located in pump box, to the “ON” position. 2. Be certain operating area around platform is clear before opening
platform. 3. Using the "UP" toggle switch, power platform up so that it is completely
out of the travel locks. 4. Using the "UP" toggle switch and "OPEN" toggle switch simultaneously,
power open platform. 5. Using the "DOWN" toggle switch, lower platform for use.
Storing platform for travel 1. With the platform open, power platform all the way up. 2. Using the “UP” toggle switch and “CLOSE” toggle switch simultaneously,
power close platform. 3. Using the “DOWN” toggle switch, power platform down past the
Travel Lock. 4. Using the “UP” toggle switch, power platform up to activate Lock Catch,
once the Travel Ear clears the slot use the “DOWN” toggle switch to lower Travel Ear into the slot.
5. Turn off power to liftgate by turning the master disconnect switch, located in pump box, to the “OFF” position.
Dock Loading 1. Turn on power to Liftgate by turning the master disconnect switch, located
in pump box, to the "ON" position. 2. Using the "UP" toggle switch, power platform up so that it is completely
out of the travel locks. 3. Using the "DOWN" toggle switch, power platform down until the platform is
level with the truck floor and hit the Dock Stops. 4. When finished Dock Loading be certain to raise platform to travel position
before pulling truck away from dock.
MAXIMUM CAPACITY
xxxx LBS.
MAXIMUM 21”
1.4 Tools Required
STEP 1 Make sure you have the following tools, equipment, and materials available: • Chalk or other marking device • Wrenches • Two 12" C-clamps • Lifting device: forklift, or overhead crane • Grinder • Welding machine • Square 24" • Tape measure
• Wire cutter or stripper
• Heat shrink gun
STEP 3 Check the corner posts and add spacers if corner posts are not flush with rear sill.
1.5 Prepare the Truck Body
STEP 1 Remove any object from the rear of the vehicle that may interfere with the liftgate.
STEP 2 Locate and mark the center of the vehicle floor and rear sill. Note! This mark will be used for
centering the liftgate.
74-1/2" Min.
Rear Sill
Floor Level
1/4" Weld X 2" Long Min. Every 12" as Shown (Both Sides of Spacers).
12" Typical
Rear cross sill of body
Floor level
90°
STEP 1 Fabricate and install support braces as shown below
14
1.6 Special Instructions for Vehicles That Do Not Meet Side Wall Requirements in 1.2
Support Brace Installation
72"
Approx.. 60"
Weld Strap to vehicle side rail or to a bolted 1/4" thick steel plate on side rail. Place the strap in line with a cross member
STEP 1 Use a forklift to position the liftgate in the work area. The side to be welded to the truck should face the rear of the truck.
Note! Be certain not to pinch hydraulic hoses while positioning liftgate on truck.
STEP 2 Put the electrical component kit aside for later installation.
STEP 3 Attach chains or hooks to the lifting bar.
STEP 4 Use an adequate lifting device to raise the liftgate to the height of the floor of the truck bed.
Recommended lifting devices: • Chain fall • Forklift • Overhead crane
STEP 5 Line up mark at center of liftgate housing with center of truck bed.
2. ATTACH THE LIFTGATE
2.1 Position the Liftgate
Make sure that battery cables are disconnected before welding to avoid damaging the truck's electrical system.
Track
16
STEP 6 Check that the top of the liftgate housing is level with the rear sill of the truck. Check the columns for squareness using a square as shown.
STEP 7 Double check columns for squareness using the diagonal measurements as shown. This is essential to ensure the smooth operation of the lift.
STEP 8 Use the 12" C-clamps to fasten the liftgate to the truck • Make any necessary adjustments to
C-clamps before welding
STEP 9 Re-check for squareness. DO NOT WELD until you are sure that: • The top of the liftgate housing is level
with the truck floor • Columns are square • The liftgate is centered between both
sides of the opening.
Note! Do not remove the lifting device yet!
Check Squareness with Horizontal & Diagonal Measurements Check Dim A = Dim D, DIM B = DIM C
17
STEP 1 Weld the liftgate directly to the reinforcing corner plate.
2.2 Weld the Liftgate to the Truck
STEP 3 Weld inside of columns to door frame.
STEP 2 Weld the outside of column to the truck.
STEP 4 Weld top of housing to sill of truck.
STEP 5 Remove clamps.
Do not remove clamps until you are sure liftgate is securely welded to truck.
STEP 6 Remove the lifting device.
STEP 7 Remove shipping feet and lifting bar.
1/4" X 2" Long Welds, 6 Places, Evenly Spaced, Both sides of the Door Frame
Stitch Weld Dock Bumper to Door Frame using 1/4" X 2" Long Welds, 4 Places; Top, Bottom, and 2 Evenly Spaced in the Middle
1/4" X 2" Long Welds, 5 Places, Evenly Spaced
STEP 1 Locate Pump Box and Battery Box if supplied.
Pump Box Frame with Pump Box
Battery Box Frame with Battery (ILD55 & ILD66 only)
ILD Series Installation Manual
19
STEP 2 Position Pump Box (and Battery Box, if fitted) on the ground beneath the position where it will be mounted to the vehicle. Use the diagrams below as a guide. In choosing the mounting position, you must ensure that:
• Pump Box cover opens toward curb-side of vehicle. • Pump Box is closer to the liftgate than the Battery Box (if fitted). • Hydraulic Hoses from liftgate reach Pump Box without strain.
Pump Box
Pump Box
B. Typical Installation for Slider-Axle Trailers
Pump Box
(Requires hydraulic hoses and wiring extension, supplied with trailer wire option.)
STEP 7 Repeat steps 1and 2 for Pump Box Frame.
STEP 4 Position Braces as shown, so that they butt against vehicle cross members.
STEP 5 Drill through ends of braces and vehicle cross members in 6 places. 3 places in front and 3 places in back. Note! Middle hole will require drill through
at the top of the battery box.
Brace
STEP 3 Use floor jack or other lifting device to raise Pump Box to vehicle cross members.
STEP 6 Bolt Battery Box brace to vehicle cross member with 1/2" grade 5 bolts and lock nuts. 6 places
Vehicle Cross Member
Brace Bolt
STEP 1 Familiarize yourself with key components for steps 1-7 using this diagram. Refer back to this diagram as needed during hydraulic hookup.
21
STEP 2 Disconnect the 3/8" hydraulic hoses from each other and connect the line as instructed below. Note! The 1/4" and 3/8" hydraulic hoses have been connected together to prevent oil from draining from the cylinders and to minimize the amount of bleeding needed when installation is complete.
STEP 3 Connect the 3/8" hydraulic hose with the 3/8" JIC female swivel to the 3/8" JIC male fitting coming out of the pump box. This is the line providing pressure to raise the platform.
4. HYDRAULIC HOOKUP
STEP 4 Connect the 3/8" hydraulic hose with the 3/8" JIC male swivel to the 3/8" JIC female fitting coming out of the pump box. This is the line providing pressure to lower platform.
STEP 5 Disconnect the 1/4" hydraulic hoses from each other.
STEP 6 Connect the 1/4" hose with the 1/4" JIC female swivel to the 1/4" JIC male fitting coming out of the pump box. This is the line providing pressure to close the platform.
3/8" JIC Male
1/4" JIC Male
3/8" JIC Female
1/4" JIC Female
22
STEP 9 Use the hose clamps provided to secure the hoses to the vehicle.
Note! Hoses must be clamped no less than every 24" to prevent chafing from over the road vibration.
STEP 7 Connect the 1/4" hose with the 1/4" JIC male swivel to the 1/4" JIC female fitting coming out of the pump box. This is the line providing pressure to open the platform.
STEP 8 Route the four hoses from the hydraulic enclosure to the liftgate. For trailer installations, all hoses should be routed rearward along the center of the trailer body.
Tie hoses together and secure to underside of truck or trailer.
5. ELECTRICAL HOOK UP (AUXILIARY BATTERIES)
5.1 Electrical Connection to Battery Box
STEP 1 ILD55 & 66: Secure three Group 31D, 925 CCA, batteries in battery box with hold-downs provided.
ILD35 & 44: Secure two Group 31D, 925 CCA, batteries in battery box with hold-downs (not provided).
STEP 2 Attach the "BAT" terminal on the circuit breakers mounted on the side of the battery box to the positive terminal on each end battery as shown in diagrams below. (One circuit breaker per liftgate motor) 2 Battery Configuration (ILD35 & 44) 3 Battery Configuration (ILD55 & 66)
STEP 3 Run #1 battery cable from “AUX” terminal on circuit breaker to the unused stud on the master disconnect. Note: The master disconnect switch should be in the “OFF” position while connecting the battery cable.
STEP 4 Run another #1 battery cable from the negative terminal (ground) of the end battery to the 3/8" bolt on the bottom of the power unit.
STEP 5 Connect charging battery cable run from the AUX. terminal on the circuit breaker connected to vehicle battery to the positive terminal of the liftgate end battery.
5.2 Secure The Cables
STEP 1 Use the nylon ties included in your Electrical Component Kit to secure any cable running underneath the vehicle as detailed in Step 2 below.
Note! If the cable is not secured properly, the warranty is null and void.
STEP 2 Secure the cable every 24", keeping it away from: • Moving parts • Heat sources (exhaust) • Road
STEP 1 Familiarize yourself with electrical components/layout in diagram below. Refer back to this diagram as needed during installation of electrical components.
Install the Circuit Breaker that you received with your liftgate.
If you use any other circuit breaker, you will void your warranty.
Battery
Circuit Breaker
To Liftgate
Plastic Cable Ties Not Shown NOTE! Two batteries are required for the ILD55 & ILD66 liftgate. Additional batteries in parallel may be required for heavy usage.
5.3 Install the Circuit Breaker
STEP 2 Find a convenient location within 24" of the battery to install the Circuit Breaker. Location should be such that: a) Cable running from positive terminal
of battery is no longer than 24". b) There is good protection against
objects coming in contact with Circuit Breaker terminals and causing a short.
c) There is easy access to the Circuit Breaker to reset it, when necessary.
STEP 3 Use the Circuit Breaker as a guide to drill pilot holes for the 1/4" sheet metal screws provided.
STEP 4 Screw the Circuit Breaker to the compartment wall.
Bill
Note
26
STEP 5 Use appropriate instruction for the model liftgate you are installing.
ILD35 & ILD44 Only – Main power to Liftgate Run the battery cable from the unused terminal on the master disconnect in the Liftgate Pump Box and attach it to the “AUX” terminal on the circuit breaker.
ILD55 & ILD66 Only – Charging line to Liftgate Battery Box. Run the battery cable from the positive terminal on the 8D battery in the Liftgate Battery Box and attach it to the “AUX” terminal on the circuit breaker.
STEP 9 Slide the shrink tube into position centered over the terminal and battery cable seam.
STEP 6 Strip battery cable casing back 1/2".
STEP 7 Slide the shrink tube over the battery cable.
STEP 8 Crimp the battery terminal provided to the stripped end of the cable.
STEP 10 Heat the shrink tube until the tube is sealed against terminal and battery cable casing.
STEP 11 Apply a protective coating of corrosion preventive compound to the connections. Note! Terminal connections may
corrode prematurely unless you apply the corrosion preventive compound.
STEP 12 Measure how long the battery cable should be to reach from the BAT terminal on the Circuit Breaker to the positive side of the battery.
STEP 13 Cut the battery cable to the correct length. Note! Measure before cutting!
STEP 14 Run the battery cable from the BAT terminal on the Circuit Breaker to the positive side of the battery. Note! To avoid short circuits:
Route the cable away from heat sources, moving parts, and possible road contact. Secure the cable under the vehicle every 24" with the plastic ties and wire clamps provided in the Electrical Component Kit.
STEP 18 Slide the shrink tube into position centered over the terminal and battery cable seam.
STEP 15 Strip battery cable casing back 1/2".
STEP 16 Slide the shrink tube over the battery cable.
STEP 17 Crimp the battery terminal provided to the stripped end of the cable.
STEP 21 Connect the positive and the negative leads to the battery.
STEP 19 Heat the shrink tube until the tube is sealed against terminal and battery cable casing.
STEP 20 Apply a protective coating of corrosion preventive compound to the connections. Note! Terminal connections may
corrode prematurely unless you apply the corrosion preventive compound.
STEP 1 Locate Column switch and Control switch wires and extend to pump box.
5.4 Install Control Switch
STEP 3 Connect the Control Switch to the mating connector on side of pump box. power unit as shown in Figures 2A & 2B on Page 29. (Column switch will not have the wires to control power open/close operation).
STEP 5 Secure the switch cables to the vehicle cross members every 24" minimum with the ties provided.
STEP 2 Connect the Column Switch to the mating connector on side of pump box.
Control Switch
Pump Box
Column switch cable from liftgate. (3 wire)
Note: Column switch and Control switch are pre-installed on passenger side slider and column.
STEP 4 Secure the battery cable(s) running to the pump box with the strain reliefs provided.
Figure 2A: ILD35 & ILD44 Wire Connection Locations
Figure 2B: ILD55 & ILD66 Wire Connection Locations
(30)
(30)
STEP 2 Make sure all lights operate properly after wiring.
All lights must be installed in accordance with all applicable DOT and other state, provincial, and federal regulations.
5.5 Wire Lights
STEP 1 Using the Wiring Schematic as a guide, wire the mating plug and harness to the vehicle’s wiring system.
Wiring Schematic
7. BLEEDING THE HYDRAULIC CYLINDERS
7.1 BLEEDING THE LIFTING CYLINDERS
STEP 1 Run the power unit until the platform is stopped at its maximum lifting height. Note: Master disconnect located in pump box must be on to run liftgate.
STEP 2 With the platform at the maximum lifting height continue to run the power unit for 35 seconds.
STEP 3 Let the power unit rest (not running) for 5 minutes and run power unit for 35 seconds again with the platform at the maximum lifting height.
STEP 4 The lifting cylinders are now bled.
33
7.2 BLEEDING THE CLOSING CYLINDER Note: If liftgate platform opens and closes without hesitation bleeding the closing cylinder is
not necessary.
STEP 3. Remove roll pin from platform cylinder pin.
STEP 4. Remove platform cylinder pin from cylinder and platform.
STEP 5. Retract POC cylinder using switch.
STEP 6. Remove hose from upper fitting of POC cylinder.
STEP 7. Run fluid through hose by operating switch as if trying to close platform. Note: Stop when fluid exiting the hose is running clear.
STEP 8. Reattach hose to upper fitting of POC cylinder.
STEP 9. Extend POC cylinder using switch.
STEP 10. Remove hose from lower fitting of POC cylinder.
STEP 11. Run fluid through hose by operating switch as if trying to open platform. Note: Stop when fluid exiting the hose is running clear.
STEP 12. Reattach hose to lower fitting of POC cylinder.
STEP 13. Align POC cylinder clevis with bracket on platform.
STEP 14. Replace the platform cylinder pin as well as the roll pin.
33a
STEP 1 Turn the Master Disconnect Switch to “ON”.
STEP 2 Open platform to horizontal position.
STEP 3 Lower the platform carefully.
STEP 4 Raise the platform.
STEP 5 Close the platform.
STEP 6 Repeat Steps 2 through 5, four times. Note! Check for:
• Unusual noises • Missing fasteners • Loosened fasteners • Broken welds • Signs of overload • Hydraulic leaks • Problems with side platform
support chains
STEP 7 Lock the liftgate in place.
STEP 8 Turn Master Disconnect Switch to OFF and make sure the liftgate will not operate.
Operating Instructions Read operating instructions before using liftgate.
Opening platform from stored position 1. Turn on power to liftgate by turning the master disconnect switch,
located in pump box, to the “ON” position. 2. Be certain operating area around platform is clear before opening
platform. 3. Using the "UP" toggle switch, power platform up so that it is completely
out of the travel locks. 4. Using the "UP" toggle switch and "OPEN" toggle switch simultaneously,
power open platform. 5. Using the "DOWN" toggle switch, lower platform for use.
Storing platform for travel 1. With the platform open, power platform all the way up. 2. Using the “UP” toggle switch and “CLOSE” toggle switch simultaneously,
power close platform. 3. Using the “DOWN” toggle switch, power platform down past the
Travel Lock. 4. Using the “UP” toggle switch, power platform up to activate Lock Catch,
once the Travel Ear clears the slot use the “DOWN” toggle switch to lower Travel Ear into the slot.
5. Turn off power to liftgate by turning the master disconnect switch, located in pump box, to the “OFF” position.
Dock Loading 1. Turn on power to Liftgate by turning the master disconnect switch,
located in pump box, to the "ON" position. 2. Using the "UP" toggle switch, power platform up so that it is completely
out of the travel locks. 3. Using the "DOWN" toggle switch, power platform down until the platform
is level with the truck floor and hit the Dock Stops. 4. When finished Dock Loading be certain to raise platform to travel
position before pulling truck away from dock.
Part No. 68242
STEP 1 Apply the decals provided to their proper positions, following the diagram below.
Decal Placement
1. Operating Instructions 2. Warning Keep Clear 3. Warning Maximum Load Capacity 4. Urgent Warning 5. Warning Liftgate Can Crush
9.2 Operation Manual
STEP 1 Write the model number and serial number of the liftgate in the Operation Manual.
STEP 2 Ensure that the Operation Manual is in the glove box of the vehicle.
STEP 1 Load the liftgate as shown in the Load Lifting Capabilities Table below, with load centered on the platform.
ILD35 3500 lbs.
ILD44 4400 lbs.
ILD55 5500 lbs.
ILD66 6600 lbs.
9.3 Final Test
STEP 2 Test the loaded liftgate. Make sure you check the items shown in Load-Testing Table below.
WHAT TO CHECK POSSIBLE PROBLEMS SOLUTIONS
Fasteners • Nuts Loose Fasteners Tighten Fasteners • Bolts Parts missing Call Customer Service• Clevis pins Parts damaged for OEM parts.• Cotter pins USA: 888-774-5844• Roller pins
Welds Cracked or broken welds Call Customer Service. USA: 888-774-5844
Hydraulic Leaks Tanks over filled Make sure the tank is not over filled
Loose fitting or Tighten loose fitting loose hydraulic line or hydraulic line
Platform is level Platform is not level. Bleed cylinders with the floor of (See Section 7, page 33) the vehicle when raised completely
Any unusual Various Call Customer Service. noise USA: 888-774-5844
Load-Testing Table
38
Severe personal injury could result if you fail to check each of the following items. DO NOT USE the liftgate if any of the following points are not checked.
Call Customer Service if you have any questions. USA: 888-774-5844
9.4 Inspect Your Installation and Document Your Inspection
NOTE Installation is not complete if you have not checked and verified the items listed on the Inspection Sheet (page 39). Note! Warranty is void if Inspection
Sheet is not complete.
STEP 1 Complete the Inspection Sheet on Page 39.
STEP 2 Keep the completed Inspection Sheet on file at the facility where the installation is performed.
Inspection Sheet
____ 1. Lifting bar and shipping feet are removed from the liftgate.
____ 2. Pump reservoir is filled to 1/2" from top when platform is fully raised to truck floor. (Automatic transmission fluid is recommended).
____ 3. All tack welds are now complete welds.
____ 4. Platform secures properly in its stowed position.
____ 5. Hydraulic components do not leak.
____ 6. Battery cable(s) attached and clamped tight and strain reliefs are on all battery cables. ____ 7. Lights wired properly and operational.
____ 8. All decals in place and legible.
____ 9. Battery grounded to power unit mount bolt. ____ 10. Platform opens properly.
____ 11. Platform travels up and down smoothly and freely, without any hesitation.
____ 12. Platform is level with the floor of the vehicle when raised completely
____ 13. Platform rests on the ground when lowered completely.
____ 14. Platform opens and closes properly and at correct speed (Between 6 and 10 seconds for each operation).
____ 15. Cables to Control Switch are secured properly.
____ 16. Circuit Breaker installed.
____ 17. Master Disconnect Switch operating properly.
____ 18. The liftgate's serial number and model number are written on the inside of the front cover of the Operator's Manual, in the space provided.
____ 19. Operator‘s Manual Kit is in the vehicle's glove box.
____ 20. Supervisor has demonstrated the instructions in the Operating Manual to the customer/driver.
Inspection Information:
15939 Piuma Ave., Cerritos, CA 90703 Tel (562) 924-8218 Fax
Visit out website at www.interlift.net for up to date inform
ILD cylinder bleed.pdf
STEP 1
STEP 2
STEP 3
STEP 4
Open Platform.
Remove roll pin from platform cylinder pin.
Remove platform cylinder pin from cylinder and platform.
Retract POC cylinder using switch.
Remove hose from upper fitting of POC cylinder.
Run fluid through hose by operating switch as if trying to c
Reattach hose to upper fitting of POC cylinder.
Extend POC cylinder using switch.
Remove hose from lower fitting of POC cylinder.
Run fluid through hose by operating switch as if trying to o
Reattach hose to lower fitting of POC cylinder.
Align POC cylinder clevis with bracket on platform.

ild installation manual

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