interlift ild - It works!

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interlift ild - It works!
INTERLIFT
ILD
INSTALLATION MANUAL
& CHECK-OFF SHEET
Rev. 1.7, Date 05-16-2012
INTERLIFT, INC. dba MBB Palfinger
15939 Piuma Ave., Cerritos, CA 90703 Tel (888)-774-5844
572 Whitehead Road, Trenton, NJ 08619
Tel (609)-587-4200
Fax (562)-924-8318
Fax (609)-587-4201
Visit our website at www.mbb-palfinger.com for up to date information and notifications
If you received this product with damaged or missing parts,
Please contact MBB Palfinger, Inc. at (888)-774-5844
ILD Plus Installation Manual
Table of Contents
1
Safety Information .................................................................................................................3
2
Important Information............................................................................................................4
3
Tools for Installation ...............................................................................................................5
4
Mounting Requirements .........................................................................................................6
5
Body Preparation ................................................................................................................. 10
6
Liftgate Installation .............................................................................................................. 15
7
6.1
Prepare Liftgate .................................................................................................................... 15
6.2
Positioning Liftgate ............................................................................................................... 16
6.3
Welding Liftgate .................................................................................................................... 19
7.1
Position Hydraulic Enclosure.................................................................................................. 22
7.2
Welding Hydraulic Enclosure ................................................................................................. 22
7.3
Hydraulic Connections ........................................................................................................... 24
7.4
Schematic (Hydraulic) ............................................................................................................ 26
Electric Installation ............................................................................................................... 30
7.1
Electric Control Harness Connection ...................................................................................... 30
7.2
Auxiliary Batteries Kit ............................................................................................................ 31
7.3
Battery Cable Connections .................................................................................................... 31
7.4
Trailer to Tractor Ground TEST ............................................................................................... 34
7.5
Schematic (Electrical) ............................................................................................................ 36
8
Decal Placement ................................................................................................................... 37
9
Cycle Test and Bleed the hydraulic system. ............................................................................ 40
10
Final Inspection Check List .................................................................................................... 43
Revision 1.7
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ILD Plus Installation Manual
1
Safety Information
This manual follows the Guidelines set forth in “ANSI Z535.4-2007” for alerting you to
possible hazards and their potential severity.
This is the safety alert symbol. It is used to alert you to potential personal injury hazards.
Obey all safety messages that follow this symbol to avoid possible injury or death.
! 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 minor
or moderate injury.
CAUTION without the safety alert symbol is used to address practices not related to personal
injury. (In this manual we use it to alert you to potentially hazardous situation which, if not
avoided, may result in property damage.)
NOTICE without the safety alert symbol is used to address practices not related to personal
injury. (In this manual we use it to alert you to special instructions, steps, or procedures.)
Revision 1.7
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ILD Plus Installation Manual
2
Important Information
Before Getting Started
“READ FIRST”
The ILD 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 connection MUST be dressed with dielectric grease or equivalent sealer.

Read and understand the “Installation Manual” and “Owner’s Manual” in their entirety
before starting your Installation.

Refer to your truck manufacturer’s instructions before adding any auxiliary equipment.

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 MBB Palfinger, Inc. 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 kept in your records
for future reference.

Verify that ALL decals are placed properly. (Contact MBB Palfinger, Inc. to replace any
missing decals)

Refer to owner’s manual for Operation and maintenance information.
Revision 1.7
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ILD Plus Installation Manual
3
Tools for Installation
Metric Wrench Set
Basic Screwdriver Set
Pliers
Wire Crimp Pliers
Test Light
Snap Ring Pliers
Hammer
½” Impact & Sockets
Sm. Metric Socket Set
Assorted Drill Bits
Metric Allen Set 1.5mm10mm
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
Min. 250 Amp Welder
Cutting Torch or Equiv.
Revision 1.7
Heat Gun or Equiv.
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ILD Plus Installation Manual
4
Mounting Requirements
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 truck body or trailer rear door does not interfere with installation or operation of liftgate ILD
series liftgate. The ILD series cannot be installed with "barn" or "swing" type doors without extensive
modification.
It is not recommended to cut, torch, or remove support materials from rear sill of truck or trailer.
Installers are advised to sub-frame or flush sills as required. Removing gussets, stiffeners, light rings,
or other such support structures may VOID your truck/trailer warranty.
Call tech support before starting the installation if you have any questions or concerns
on mounting dimensions or procedures… 888-774-5844
Revision 1.7
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ILD Plus Installation Manual
Step 1
Measure Floor Height and determine clearance requirements for your liftgate platform size.
Step 2
Check chart below to ensure that your gate is compatible with bed height of the vehicle.
10"
12"
74-1/2"
Bed Level
15-1/4"
58" Max.
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”
102” Over All Width liftgates (86” wide platforms) use the chart above.
Revision 1.7
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ILD Plus Installation Manual
Step 3
Determine body side wall, corner post, and rear sill strength requirements.
Truck body or trailer must be capable of supporting minimum forces and loads shown below.
X
X
Z
Y
Z
Y
X=Side Wall Tension
Y=Side Wall Compression
Z=Side Wall Shear
Revision 1.7
Side Wall Requirements Chart
ILD35
ILD44
1900 lbs.
2400 lbs.
1900 lbs.
2400 lbs.
2700 lbs.
3100 lbs.
ILD55
2950 lbs.
2950 lbs.
3800 lbs.
ILD66
3500 lbs.
3500 lbs.
4300 lbs.
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ILD Plus Installation Manual
Step 4
Determine liftgate width requirements
The ILD series liftgate is offered in two standard widths for 96” and 102” wide bodies.
Outside Frame Width
Inside Frame Width
74-1/2"
Bed Height
15-1/4"
Nominal
Truck or Trailer Width
96” Wide Body
102” Wide Body
Revision 1.7
Liftgate
Outside Frame
94”
100”
Liftgate
Inside Frame
84”
90”
Liftgate
Platform Width
80”
86”
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ILD Plus Installation Manual
5
Body Preparation
Step 1
Remove any sill or corner post mounted lights, grab handles, or bumpers. Your goal is to have a flat
and flush mounting surface for the liftgate.
Truck and trailers applications with flush corner post and sill and NO protruding gussets or stiffeners
are the most straight forward of all ILD installations. Rear of body should be 90` to ground as shown.
It is not recommended to cut, torch, or remove support materials from rear sill of truck or
trailer. Installers are advised to sub-frame or flush sills as required. Removing gussets,
stiffeners, light rings, or other such support structures may VOID your truck body or trailer
warranty.
Step 2
Be certain that under ride bumpers, trailer hitches, or other auxiliary equipment do not extend
rearward of rear sill. Use the following illustrations as a guide.
Bed Level
Bed Level
Rear Sill
Rear Sill
Rear Bumper
Needs to be mounted
Flush with Sill.
Rear Bumper
Flush with sill.
90°
Revision 1.7
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ILD Plus Installation Manual
Step 3
Trailer Hitches are common truck or trailer equipment and are compatible the ILD series.
Two considerations for mounting or moving are;
Hitch can NOT extend rearward of rear sill and liftgate will extend rearward an additional 12”.
Bed Level
Rear Sill
Hitch or other Equipment must NOT
extend rearward of rear sill.
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ILD Plus Installation Manual
Step 4
Some trailer configurations will have irregular shaped sills. Liftgate mounting surface may NOT be
flush with corner post. Some sills may be inset or have door gutters. All these situations are
remedied with a process called sub-framing and/or flushing the sill.
Sub-framing is done one of two ways; Sub-frame can be built up using correct size 3/16” or greater
wall tubing before liftgate is mounted. Or, the liftgate can be mounted into position and sub-frame can
be built as liftgate is installed with 3/16” or greater flat bar. In either case, liftgate installation weld
procedure does not change. These examples are show below.
Flushing floor or filling gap between Sill and liftgate can be done up to 6” without cross supports. Use
¼” or greater flat bar or diamond plate to span gap.
Corner Post
Gap between Sill and Liftgate
Bed Level
Liftgate Mounting Surface
Corner Stiffener
Liftgate Platform Surface
Light Box
Corner Post
Corner Post
Sub-Frame Flat Bar
Sub-Frame
Liftgate
Liftgate
Tubing sub-frame
Revision 1.7
Flat Bar sub-frame
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ILD Plus Installation Manual
Step 5
Corner stiffeners are common and should NOT be removed. It is recommended to “flat bar” with
same thickness as stiffener. Typically ¼” to 3/8” thick x 4” to 5” wide. Liftgate Installation weld
procedure is the same.
Flat Bar
Corner Stiffener
Flat Bar
Flat Bar
Corner Stiffener
Revision 1.7
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ILD Plus Installation Manual
Step 6
Side supports can be used to strengthen body.
Refer to Mounting Requirements Step 3.
Step 7
Flat bed installation may use similar arrangement with 3/16” x 4” x 4” Min. tubing for corner post and
3” channel for support bar.
Support Bar
1/4" x 3" Min. Flat Bar
1/4" x 100% weld each end
72"
Sub-plate for alum side rails
1/4" x 4" Min. bolted either side
of body cross member.
Approx. 60"
Revision 1.7
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ILD Plus Installation Manual
6
Liftgate Installation
6.1
Prepare Liftgate
Step 1
Remove hydraulic/battery enclosure form liftgate shipping assembly package.
Step 2
Remove shipping ties from all electrical harnesses and hydraulics lines and position so NOT to
interfere with position of liftgate to body or welding processes.
Step 3
Lower shipping feet may have to be removed for installation on some deep sills measuring more than
10” top to bottom.
Step 4
Weld two (2) supports to cross beam. This will help ensure even alignment between liftgate
crossbeam and body sill. Use 3” angle or channel approx 10” long.
Note: steps 2, 3 & 4 are best done with liftgate hoisted with forklift or crane. This brings items to be
addressed to working level.
Never position any portion of body under liftgate.
Remove Hydraulic enclosure
Bed Height Support Channel
Revision 1.7
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ILD Plus Installation Manual
6.2 Positioning Liftgate
Before positioning the liftgate. Consider when measuring and centering the liftgate that the
truck or trailer may NOT be square or parallel. Special care must be taken to insure that the
liftgate is square and parallel before welding.
Step 1
Truck should be on level and even ground. Uneven ground will give misleading measurements and
can cause body twist or racking.
Step 2
Preferred method for lifting liftgate is with a forklift. Position forks to widest point and lift from center.
12” or larger “C” or “F” style clamps can be used to coach or hold liftgate in position.
Step 3
Use 4”x 4” x 24” wood spacers as shown. This will help force top of liftgate tight against body for
welding. Should you need to force bottom portion, remove wood spacer and use the forklift against
the lower portion of liftgate.
Step 4
Preferred method for centering liftgate is measuring side clearances from outside of liftgate to outside
of body. (centerline marked on sill is NOT easily visible.)
Step 5
Verify all mounting dimensions, double check that floor and threshold extension are flush.
Never remove lifting device until liftgate is fully welded.
4x4x24 Wood block
Forklift forks
Bed Height Support Channel
Bed Level
90°
Revision 1.7
Forklift not shown
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ILD Plus Installation Manual
6.3
Above Floor Installation
Mount the liftgate up to 6” above floor level (as shown in figure 1). Install the gate per the
Installation Instructions.
Do not weld the traverse yet!
Figure. 1 Initial install
Traverse Floor Height
Vehicle Floor Height
After the columns have been welded in place, remove the 4 traverse bolts, and lower the
traverse to be flush with the floor. Weld into position according to the installation manual.
Also weld the traverse to each column, ¼” weld by ½” long, x3 on each side.
Traverse
After install, lower
traverse to be level
with vehicle floor.
Traverse bolts
The above floor installation reduces the bed height limit of the lift gate.
The maximum travel of the platform is 56”. For example: if the gate is
mounted 6” above floor, the maximum bed height lowers to 50”.
Revision 1.7
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ILD Plus Installation Manual
Step 6
Check liftgate to be certain it is square and parallel. Use a 3 ft carpenters square to check
column to threshold.
Step 7
Use to “Dim A” and “Dim B” to verify columns are parallel.
Step 8
Use “Dim C” and “Dim D” to verify columns are square.
Step 9
Check that columns are also 90 degrees to sill or body.
DO NOT WELD until all dimensions are checked and rechecked after each positioning
adjustment.
Dim "A"
Dim "C"
Dim "D"
Square
Dim "B"
Revision 1.7
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ILD Plus Installation Manual
6.3
Welding Liftgate
Step 1
Using ¼” x 2” welds, place one weld ½” from the top of each column on the outside and place one
weld at the bottom of each dock bumper plate.
STOP and recheck all mounting dimensions from “Position Liftgate” section.
Step 2
Final welding for the outside of liftgate is ¼” x 100% on dock bumpers and ¼” x 2” x 5 places evenly
spaced on columns top to bottom.
¼” x 2” Weld
5 places evenly spaced
Keep this area clear of
welds – Danger of
burning the switch
¼” x 100% Weld
Dock Bumper Only
Revision 1.7
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ILD Plus Installation Manual
Step 3
Weld inside of columns ¼” x 2” x 5 places evenly spaced top to bottom.
Step 4
Weld threshold ¼” x 2” x 5 places evenly spaced left to right.
¼” x 2” Weld
5 places evenly spaced
¼” x 2” Weld
5 places evenly spaced
Revision 1.7
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ILD Plus Installation Manual
IMPORTANT !
ADDENDUM TO WELDING INSTRUCTIONS
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ILD Plus Installation Manual
7
Hydraulic Installation
7.1
Position Hydraulic Enclosure
When possible, the hydraulic enclosure is positioned to be accessed from the curb side of the
vehicle. Access door of enclosure is positioned 6” in from side of body. Also, it is
recommended to position the hydraulic enclosure towards center of wheelbase and forward of
the rear wheels when possible.
-
Recommended lifting device for the hydraulic enclosure is by forklift. Be certain NOT to
damage hydraulic fittings on bottom of enclosure.
-
Standard hose kit (shipped standard with liftgate) places the front of the enclosure a
maximum of 9 feet forward from the rear of the body.
-
Relocation kit #1 (one additional 9 ft hose) place the front of the enclosure a maximum
of 18 feet forward from the rear of the body.(Recommended for 28’ to 35’ trailers)
-
Relocation kit #2 (two additional 9 ft hoses) place the front of the enclosure a maximum
of 27 feet forward from the rear of the body. (Recommended for 48’ to 53’ Trailers)
-Standard hose kit / 9ft MAX
(shipped standard with liftgate)
-Relocation kit #1 / 18ft MAX
-Relocation kit #2 / 27ft MAX
Revision 1.7
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ILD Plus Installation Manual
7.2 Welding Hydraulic Enclosure
Step 1
Weld enclosure to body cross members with ¼” x 2” welds. Weld front and rear of mounting angles at
front and rear of enclosure at each cross member. Minimum of four (4) cross members. Minimum ¼”
x 2” welds x sixteen (16) places.
Applications with Aluminum cross members will need to be bolted. Contact MBB Palfinger,
Inc. Tech Support for instructions at 888-774-5844.
¼” x 2” Weld
Four (4) Cross Members Min.
Sixteen (16) places total.
Revision 1.7
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ILD Plus Installation Manual
7.3
Hydraulic Connections
To prevent leaks during shipping and storage, hydraulic connections at liftgate are plugged by
connecting hydraulic lines together. DO NOT disconnect until you are ready to connect hoses
to liftgate and hydraulic enclosure.
Step 1
Determine best routing for hydraulic hoses. Best routing is down the center of the vehicle. However,
some applications this may NOT be possible. In these applications, running the hose channels to
outside of the frame rails may be necessary. Position the hose channel between tires.
Step 2
Weld the hose channel to body cross members. Use 1/8” x 1” welds places every 12” min. both sides.
DO NOT weld channel with hydraulic hoses or electrical wires installed.
Applications with Aluminum cross members will need to be bolted. Contact MBB Palfinger,
Inc. Tech Support for instructions at 888-774-5844.
Revision 1.7
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ILD Plus Installation Manual
Take care not to route hoses, wires, harnesses, and cables near, around, or in contact with sharp
edges, air lines, vehicle electrical, exhaust system or fuel lines.
Step 3
Route four (4) hydraulic hoses through hose channel. Position hoses opposite to each other. 3/8”
hoses should have one male and one female exposed at each end. Position ¼” hoses in the same
manor, one male and one female at each end.
Step 4
Connect hydraulic hoses to the curb side of the liftgate. The hose bundle should have four (4) hoses,
one (1) 3/8” male, one (1) 3/8” female, one (1) ¼” male, and one (1) ¼” female. The liftgate will have
the same combination of connections. There is only one combination for each connection.
Connecting:
Each Connection for the hoses on the Pump have a Letter (right to left: A, B, C, D). Connect them in
the right way, seen on both pictures below.
The two 3/8” hoses in the lift gate will be secured to each other for packaging. These need to be
disconnected to expose the male and female fittings. HYDRAULIC FLUID WILL ESCAPE FROM
THE HOSES WHEN DISCONNECTED! Be ready to make the connections to limit the amount of
escaping fluid.
Step 4
Connect hydraulic hoses to the bottom of the Power Pack Box. The hose bundle should have four (4)
hoses, one (1) 3/8” male, one (1) 3/8” female, one (1) ¼” male, and one (1) ¼” female. The box will
have the same combination of connections. There is only one combination for each connection. Refer
to the pictures below.
D ¼” OpenClose Cylinder
OPEN hose
DC B A
D
A 3/8” Lift Cylinder
up hose
C ¼” OpenClose Cylinder
CLOSE hose
Battery- and Power Pack Box
Revision 1.7
C
A
B 3/8” Lift Cylinder
down hose
Curb Side of Liftgate
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ILD Plus Installation Manual
7.4
Hydraulic Schematics (1st, 2nd and 3rd Generation pump setup)
1st Generation Pump setup
Revision 1.7
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ILD Plus Installation Manual
2nd Generation Pump setup
Revision 1.7
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ILD Plus Installation Manual
3rd Generation Pump setup
Revision 1.7
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ILD Plus Installation Manual
The following drawing shows where the different function valves can be physically found.
Main pump & motor setup with operating valves
Hydraulic Fluid Installed at Factory:
ARCTIC FLO
Typical Physical Specifications:
Gravity, API
Pour Pt. ºF
Flash Pt. ºF C.O.C.
Viscosity:
SUS @210ºF
[email protected] 100ºF
cST @ 100ºC
cST @ 40ºC
Viscosity Index
(Hours to 2. Neut.NO.)
30.4
<-85
320
41.6
97
4.65
19.66
172
2500
Prefilled hydraulic oil and specification sheet
Revision 1.7
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ILD Plus Installation Manual
7
Electric Installation
7.1
Electric Control Harness Connection
Take care not to route hoses, wires, harnesses, and cables near, around, or in contact with
sharp edges, air lines, vehicle electrical, exhaust system or fuel lines.
Step 1
Route control harness through the hose channel. This harness has plug and play connections. No
stripping of wires is required. Plug to circuit board as shown.
Control Power wiring setup from Switch/Battery to PC-Board.
Optional:
Main power
on/off switch
Control Power 4-Wire Cable
Truck Application-Always wire to truck battery
Trailer Application-wire to aux. battery
20 Amp
In-Line
Fuse
+
+
Revision 1.7
-
Wires marked
#2;#4 (Black)
go to hot,
#1 and green/yellow
go to ground
PC-board
gr/ye
#1
+E- +E
#2 #4
J2 Plug
-
15 Amp fuses
2 27
J1 Plug
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ILD Plus Installation Manual
7.2



Auxiliary Batteries Kit
Three (3) batteries are always recommended for ILD55 & ILD66.
Three (3) batteries are always recommended for high cycle and max load applications.
Three (3) batteries are always recommended for city deliveries with short duration
between stops.
Step 1
Install Batteries into hydraulic enclosure with positive terminals to the right side as shown. Use clamp
bar and mounting bolts to secure batteries.
Step 2
Use 11” parallel cables supplied to connect all positive and negative terminals as shown in next
section.
Step 3
Secure pump cables and charging cables per truck or trailer kits as show in next section.
Mounting Bolts
Clamp Bar
Positive Terminal
To Right Side
Nut & Washer
Revision 1.7
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ILD Plus Installation Manual
7.3



Battery Cable Connections
Be certain master disconnect switch is in the OFF position.
Ground cable is installed LAST.
Take care not to route hoses, wires, harnesses, and cables near, around, or in contact with
sharp edges, air lines, vehicle electrical, exhaust system or fuel lines.
The ILD 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 connection MUST be
dressed with dielectric grease or equivalent sealer.
Wiring diagram (Standard Truck Kit)
Step 1
Check for 2 gauge ground cable or heavier connecting truck batteries to chassis. If NOT supplied by
the manufacturer, one will need to be installed. Be sure to grind off paint or under coat and seal.
Step 2
Route charge cable to truck batteries as shown and secure with clips and ties supplied.
Step 3
Route ground cable from enclosure terminal to chassis frame. Be sure to grind off paint or under coat
and seal connection.
Ground to Chassis
Charging
Circuit Breaker
Auto Reset
Charging
Circuit Breaker
Auto Reset
40 ft
Ground to Chassis
Box Ground
Treminal
50"
Truck Batteries
Motor
Circuit Breakers
Flag Reset
Starter Solenoid 1
24"
Motor 1
11"
36"
Master Shut Off
Switch
50"
Truck Kit - Single Pump
Revision 1.7
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ILD Plus Installation Manual
Wiring diagram (Auxiliary Battery Truck Kit)
Step 1
Check for 2 gauge ground cable or heavier connecting truck batteries to chassis. If NOT supplied by
the manufacturer, one will need to be installed. Be sure to grind off paint or under coat and seal.
Step 2
Route charge cable to truck batteries as shown and secure with clips and ties supplied.
Step 3
Route ground cable from enclosure terminal to chassis frame. Be sure to grind off paint or under coat
and seal connection.
Ground to Chassis
Optional
Isolator
Solenoid
Circuit Breaker
Flag Reset
Charging
Circuit Breaker
Auto Reset
Ground to Chassis
40 ft
Box Ground
Treminal
36"
36"
50"
Truck Batteries
Motor
Circuit Breaker
Flag Reset
11"
Starter Solenoid 1
11"
11"
Master Shut Off
Switch
24"
12v Battery
Motor 1
50"
Truck Kit - Single Pump - Aux Battery
Ground to Chassis
Circuit Breaker
Flag Reset
Optional
Isolator
Solenoid
Charging
Circuit Breaker
Auto Reset
Ground to Chassis
40 ft
Box Ground
Treminal
36"
36"
36"
50"
Motor
Circuit Breakers
Flag Reset
Truck Batteries
Starter Solenoid 2
24"
11"
Motor 2
Starter Solenoid 1
11"
11"
Master Shut Off
Switch
24"
12v Battery
Motor 1
36"
36"
Truck Kit - Dual Pump - Aux Battery
Revision 1.7
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ILD Plus Installation Manual
Wiring diagram (Auxiliary Battery Trailer Kit)
Step 1
Run charging cable to front of trailer and install single pole socket in front bulkhead.
Step 2
Route ground cable from enclosure terminal to trailer side rail. Drill 3/8” hole and use supplied
mounting hardware. Be sure to grind off paint or under coat and seal connection.
Step 3 (optional)
For dual pole sockets, route ground cable from back of socket to fifth-wheel chassis. Be sure to grind
off paint or under coat and seal connection.
40 ft
Charging
Circuit Breaker
Auto Reset
Trailer Socket
Single & Dual Pole
40 ft
Box Ground
Treminal
36"
36"
Motor
Circuit Breakers
Flag Reset
50"
11"
Starter Solenoid 1
11"
11"
Master Shut Off
Switch
24"
12v Battery
Motor 1
50"
Trailer Kit - Single Pump - Aux Battery
Ground to Trailer
Side Rail
40 ft
Charging
Circuit Breaker
Auto Reset
Trailer Socket
Single & Dual Pole
40 ft
Box Ground
Treminal
36"
36"
36"
50"
Motor
Circuit Breakers
Flag Reset
Starter Solenoid 2
24"
11"
Motor 2
Starter Solenoid 1
11"
11"
Master Shut Off
Switch
24"
Motor 1
12v Battery
36"
36"
Trailer Kit - Dual Pump - Aux Battery
Revision 1.7
Ground to Trailer
Side Rail
Page 34
ILD Plus Installation Manual
7.4
Trailer to Tractor Ground TEST
CROSS TEST ON ENTIRE CHARGE SYSTEM
SINGLE POLE PLUG SET UP
b
a
cb
a 12 Volt lead from tractor coil cord
b Center (+) plug on front of trailer
c Trailer ground on front of trailer
d Tractor chassis ground
d
c
c
cb
Testing of full system using a battery load tester:
Start with testing each individual battery on both tractor and trailer before proceding
to check the system:
Tractor Test:
1. Ground battery load tester on tractor chassis point (d)
Hook up positive load tester cable on positive pole of single
pole plug at end of tractor coil cord (a)
Run load test- This will test entire circuit on tractor including ground
from batteries to tractor chassis
Trailer Test:
2. Ground battery load tester on trailer chassis (c)
Hook up positive cable on positive pole of single pole plug
recepticable on trailer (b)
Run load test - This will test entire circuit on trailer including circuit breakers &
ground between trailer batteries and trailer chassis.
Tractor and Trailer charging system test while connected:
3. Ground battery load tester on tractor chassis (d)
Hook up positive cable on positive pole of single pole plug
recepticable on trailer (b)
Run load test- This will test entire circuit on tractor - trailer including
ground between tractor and trailer and circuit breaker on trailer.
A simple low amp voltage test at the front of the trailer or at the tractor
will not show insufficient connections or ground problems
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Schematic (Electrical)
ILD Plus
Volt
Gauge
7.5
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7.7
Liftgate Tail Light kit / Dock Bumper Install
All truck or trailer lighting, auxiliary lighting, and reflectors must be in accordance with DOT,
State, and Federal regulations.
Step 1
Use the wiring schematic below as a guide for the liftgate light kit hookups.
Dock Bumper Installation
(Bumper must be able to slide Up and Down easily)
Dock Bumper
Retaining Nut
Retaining Bolt
Install bumper from the bottom.
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8
Decal Placement
For operator’s safety, all decals appearing in “Decal Kit” must be in a conspicuous place on control
side of liftgate to be read by operator. This is typically a combination of decals on the liftgate and truck
body. Please make sure to place the maximum capacity decal (D) on driver and curb side.
(A) 1 ATG OPER-ILD - Operating Instructions
(B) 1 ATG-SWILD - Main Operation Switch
(C) 1 ATG-OPENILD - Notice for Open & Close
(D) 2 ATG-XXXX - Max. Capacity (please check the serial number plate to find out your specific
capacity)
(E) 1 ATG-URGWA - Urgent warning: Elevating gate instructions
(F) 2 ATG-WLH - Warning: liftgate can crush
(G) 1 decal - Warning: Always stand clear of platform area.
(G) 1 ATG-BKR - Circuit Breaker Reset (must be located at the circuit breaker)
(H) 1 ATG-RESET - Circuit Breaker Protection
(J) 2 ATG-CTN - Caution: Always stand clear of platform area
(K) 1 ATG-CAB - Liftgate Shut-Off (Place Decal next to the On-Off Switch in the Cab)
Decal - D
Decal - C
Decal - B
Decal - G
Decal - A
Decal - F
Decal - H
Decal - E
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Decal - J
Decal - K
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Step 1
Decals are adhered in a conspicuous place near main controls as shown below.
Decal D
Decal J
Decal A
Decal C
Decal E
Decal B
Decal H
Decal J
Decal F
Decal G
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9
Cycle Test and Bleed the hydraulic system.
Improper use of the liftgate may result in serious injury. DO NOT operate this liftgate without
being properly instructed and fully understanding the Owners manual.
Step 1
Turn on power to liftgate by turning the master disconnect switch, located in battery box, to the “ON”
position.
Platform may crush or pinch. Make certain area around liftgate is clear during all times of
operation.
Step 2
Open Liftgate Platform.
Be certain operating area around platform is clear before opening platform.
Pushing the “UP” button, raise the platform up so that it is completely out of the travel locks.
Test steps 2 through 9 a minimum of five (5) times each to ensure NO unusual noises or
movements are found. This will confirm all controls work correctly and hydraulic system is
completely bled of air.
UP / Raise
Button
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Travel Lock
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Step 2 (continued)
Open Liftgate Platform.
Be certain operating area around platform is clear before opening platform.
Pushing the “DOWN” button, and “OPEN” button together, power the platform open.
Open/Close Button
Down / Lower
Button
Step 3
Lower the platform to the ground.
Be certain operating area around platform is clear before opening platform.
Pushing the “DOWN” button, lower the platform to the ground.
Note: for power down operation, push the down button twice (within 3 seconds).
Down / Lower
Button
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Step 4
Raise the platform to bed level.
Be certain operating area around platform is clear before opening platform.
Pushing the “UP” button, raise the platform to bed level.
Step 5
Bleeding the system.
With the platform at bed level, push the “UP” button for thirty (30) seconds. This will bypass hydraulic
fluid through hydraulic poppet valves located in each of the lift cylinder pistons returning hydraulic fluid
back to the reservoir via the return lines.
UP / Raise
Button
Step 6
Closing and Storing of the Platform for transit.
Be certain operating area around platform is clear before opening platform.
With the platform open at bed level use the “UP” button and “CLOSE” button together, power the
platform closed.
UP / Raise
Button
Open/Close
Button
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Step 7
Using the “DOWN” button, push down twice (within 3 seconds) and power down platform past the
Travel Locks. (See Illustration)
Down / Lower
Button
Step 8
Using the “UP” button, raise platform up until travel ears clear the travel lock slot.(See Illustration)
Up / Raise
Button
Step 9
Once the travel ear clears the slot, use the down button twice (within 3 seconds) to power down
travel ear into travel lock slot.
Down / Lower
Button
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10
Final Inspection Check List
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 filed at the facility
where liftgate was installed.
Structural Inspection
Lifting bar and shipping feet are removed from the liftgate.
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 square and parallel per this manual.
Hydraulic Inspection
Pump reservoir is filled to 1" from top when platform is fully raised to truck floor.
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.
Electrical Inspection
Master Disconnect Switch is installed and operating properly.
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.
Circuit Breakers installed and wired per instructions.
Lights wired properly and operate per DOT, State, and Federal requirements.
Load test is preformed per Trailer to Tractor grounding TEST on Page 33.
Operational Inspection
All decals are in place and legible per instructions.
All pivot points are lubricated per instructions.
Platform secures properly in its stowed position latches.
Platform powers down and locks hydraulically in latches.
Platform travels up and down smoothly and freely, without any hesitation or unusual noises.
Platform is level with the floor of the vehicle when raised completely.
Platform rests on the ground evenly when lowered completely.
Platform opens and closes properly and at correct speed (Between 6 and 10 seconds for each operation).
The liftgate serial number and model number are documented on the inside of the front cover of the
Owners Manual, in the space provided.
Owners Manual is in the vehicle's glove box (or hydraulic enclosure on trailers)
Supervisor has demonstrated the instructions in the Owners Manual to the customer/driver upon delivery.
Inspection Information:
Name (please print): ____________________________________________________________
Completed by: ________________________________________________________________
(signature)
Title: ______________________________________________ Date: _____________________
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