ILT / ILT-WR / ILT-PD

ILT / ILT-WR / ILT-PD INSTALLATION MANUAL

& CHECK-OFF SHEET ECN-M0275 Rev. 1.11, Date 08-01-2013. Part #90-1013-000

PALFINGER Liftgates, LLC. 15939 Piuma Ave., Cerritos, CA 90703

Tel (888)-774-5844 Fax (562)-924-8318

PALFINGER Liftgates, LLC. 572 Whitehead Road, Trenton, NJ 08619

Tel (609)-587-4200 Fax (609)-587-4201

Visit our website at www.palfinger.com for up to date information and notifications

If you received this product with damaged or missing parts,

Please contact PALFINGER Liftgates at (888)-774-5844

-i-

Company Information:

Company Name:

Advisor Name:

Truck/Trailer Year Make & Model:

Liftgate Information:

Liftgate Serial Number:

Liftgate Model Number:

Date of Purchase:

Date of Installation:

ILT Installation Manual

Revision 1.11 - ii -

Table of contents

1 Safety Information .................................................................................................................... 1

2 Important Information ............................................................................................................... 2

3 Tools For Installation ................................................................................................................ 4

4 General View of Liftgate ........................................................................................................... 5

4.1 General Figures ............................................................................................................ 5

5 Installation Dimensions ............................................................................................................ 8

5.1 Important Dimensions ................................................................................................... 10

5.2 Installation Dimensions 900mm arm ILT ........................................................................ 11

6 Chassis and Body Preparation ................................................................................................ 12

6.1 Rear Cutout ................................................................................................................... 12

6.2 Bed Extension Installation ............................................................................................. 14

6.3 Dock Bumper Installation (Optional) .............................................................................. 15

6.4 ILT with Walk Ramp (Optional) ...................................................................................... 17

7 Gate Installation ........................................................................................................................ 18

7.1 Frame Installation .......................................................................................................... 18

7.2 Bolt-on setup ................................................................................................................. 20

7.3 Adjusting the Platform ................................................................................................... 21

7.4 Final steps of installation ............................................................................................... 22

8 Electrical Installation ................................................................................................................ 25

8.1 Main Power Connections............................................................................................... 25

8.2 Circuit Breaker .............................................................................................................. 25

8.3 UP/DOWN Switch Installation ....................................................................................... 26

8.4 ON/OFF Switch ............................................................................................................. 28

8.5 Remote Hand Control Installation (Optional) ................................................................. 28

8.6 Wiring Diagram (Main battery wiring) ............................................................................ 29

8.7 Wiring Diagram (Gravity Down) ..................................................................................... 30

8.8 Wiring Diagram (Power down ) ...................................................................................... 31

9 Lubrication and Final Inspection ............................................................................................. 33

Hydraulic Schematic (Gravity Down) ........................................................................................... 35

9.1 Hydraulic Schematic (Power down) ............................................................................... 36

9.2 Decal Placement and Inspection ................................................................................... 38

10 Final Inspection Check List ...................................................................................................... 41

ILT Installation Manual Chapter 1

Revision 1.11 - 1 -

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 1.11 - 2 -

2 Important Information

Before Getting Started

“READ FIRST”

The ILT liftgate is a heavy duty industrial hydraulic lifting device. Performance and reliability are closely related to proper installation, battery cable connections, and grounding. All grounding surfaces MUST be cleaned, prepped, and sealed per this manual. “Cut to size” cables MUST be properly crimped and sealed as factory supplied. All connections MUST be dressed with dielectric grease or equivalent sealer.

• 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. Installer is responsible for compliance with this manual, OEM and FMVSS requirements.

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

• Always Ground closest to your welding point to prevent arcing through moving parts or electrical parts.

• Contact PALFINGER Liftgates for Special Installations not covered in this Installation Manual.

• Do not paint cylinder shafts or nylon bearings (Use non-chlorinated brake cleaner to remove over spray)

• Final Check-Off-Sheet at rear of this manual MUST be filled out and kept in your records for future reference.

• Refer to owner’s manual for Operation and maintenance information.


Revision 1.11 - 3 -

Improper operation of this liftgate may result in severe personal injury or death. DO NOT op-erate unless you have been properly instructed, have read and are familiar with the proce-dures in this manual. This manual has been designed to illustrate the steps needed for the basic installation of the ILT liftgate. It also provides safety information and simple preventive maintenance tips.

This manual is not intended for use as a repair or troubleshooting guide. Repairs should be performed by a PALFINGER Liftgates Authorized Service Center. This Manual has been designed for use in conjunction with the ILT series liftgate only which is de-signed for different capacities. There are four options available to determine the model and serial number of the installed liftgate: 1) Refer to the serial number tag on the liftgate (Driver Side on Top of Mount Frame- See the figure below). 2) Ask your employer or lessor; 3) Call your PALFINGER Liftgates Authorized Service Center for assistance. 4) Call PALFINGER Liftgates for assistance in the USA at 888-774-5844. You can also contact PALFINGER Liftgates by fax (562) 924-8318 or on the internet- www.palfinger.com

For technical support, contact PALFINGER Liftgates or an authorized PALFINGER service center. www.palfinger.com Replacement manuals are available at no charge by contacting Customer service at 888-774-5844

Location of

Nameplate


Revision 1.11 - 4 -

3 Tools For Installation

Metric Wrench Set Basic Screwdrivers Assorted Pliers Wire Crimp Pliers

Digital Multi-Meter Snap Ring Pliers Hammer SAE & Metric Allen key Set

½” Impact & Sockets SAE & Metric Socket

Set

Assorted Drill

Bits

Floor Jack or Equiv.

Sm. To Med. Bottle

Jack

Forklift or O/H Crane Hand Held

Grinder

Paint Gun & Accessories

Pry Bar 3/8 Drill Motor Grease Gun Heat Gun or Equiv.

Min. 250 Amp Welder Cutting Torch or Equiv.

Table 3-1:Suggested Installation Tools


Revision 1.11 - 5 -

4 General View of Liftgate

4.1 General Figures

Figure 4-1: ILT Twinfold, general view

PARALLEL ARM

SINGLE ACTION

LIFT CYLINDERS

PARALLEL ARM

LIFT ARM

GRAVITY DOWN

HYDRAULIC POWER UNIT

(inside tube)

MOUNT FRAME

LOAD CENTER OF

GRAVITY

CART STOPS (optional)

BUMPER

PLATFORM TIP

NAMEPLATE


Revision 1.11 - 6 -

Figure 4-2: ILT-WR (All Aluminum), general view

WALK RAMP

LATCH

SADDLE

UP STOPS

SLIDER

PADS

ALUMINUM

MAIN SECTION

BUMPER

MOUNT FRAME

PARALLEL ARM

LIFT ARM

GRAVITY DOWN


(inside tube)

PLATFORM TIP CART STOPS (optional)

SINGLE ACTION

LIFT CYLINDERS


Revision 1.11 - 7 -

Figure 4-3: ILT Power Down, general view

PARALLEL ARM

DOUBLE ACTION LIFT CYLINDERS

PARALLEL ARM

LIFT ARM

MOUNT FRAME

LOAD CENTER OF

GRAVITY

CART STOPS (optional)

POWER DOWN


(inside tube)

BUMPER

PLATFORM TIP


Revision 1.11 - 8 -

5 Installation Dimensions

Quote#/PO#......................_________________________

Company…………………_________________________

Phone………(___) ___-____ Fax……….(___) ___-____

Email………..……._________________@____________

Type of Body (check one)

Van

Flatbed

Refer

VIN #:__________________________ Trailer Make:______________ GVWR______________ Length______

Liftgate Model:________________________ Liftgate Capacity:_____________

Liftgate platform dimensions:_________________

A = Bedheight: top of trailer floor to level ground (with air bags up)…...……………………__________

B = Top of floor to bottom of trailer cross member.………………..…………………………..__________

C = rear sill height: top of floor to bottom of buck plate……..…………………………………__________

D = Crossmember height……………………………………………….……………………...…__________

E = Tire to end of body……………………………………………………………………………__________

F = Bogie to end of body ……………………………………………………………….………..__________

Sliding suspension? Y / N (IF YES complete G, H, I, K, and L dimensions)

G = Inside hroizontal width of sliding suspension channels.……………………………….…__________

H =Diamter of sliding suspension holes…………………………………………………………__________

I = Hole spacing……………………………………………………………………………………__________

J = Bottom of cross members to bottom of sliding ramb box if equiped………………….….__________

K = Rear sil face to first slider hole………………………………………………………………__________

L = Top of floor, where liftgate platform will meet floor to the center of the trailer slider hole_________

X = Eyebrow depth…………………………………………………………………………………._________

Z = Top of floor, where the liftgate platformw ill meet to the top of the eyebrow…………….._________

Type of Rear door (check one)

Roll-up

Swing

Flip-up

Chassis Information

Chassis Dimension Sheet

Trailer

Contact Information


Revision 1.11 - 9 -

Quote#/PO#……………………………………………………….______________________________

Company…………………………………………………………..______________________________

Phone………………………………………………(____) ____-_____ Fax……….(____) ____-_____

Email………..………………………………………………………________________@____________

Type of Body (check one)

Van

Flatbed

Refer

VIN #:______________________________ Truck Make:_____________ GVWR____________

Liftgate Model:________________________ Liftgate Capacity:_____________

Liftgate platform dimensions:_________________

A = Bedheight………………______ Loaded BedHeight……………...…______

B = Top of floor to bottom of frame……………….………………………..…______

C = Rear sill height…………………………………………………….…….…______

D = Spring hanger to end of body……………………………………….…....______

E = Tire to end of body……………………………………………………....…______

J = Gas tank to end of body (if applicable)…………………………...….......______

K = Bottom of frame to bottom of gas tank (if applicable)……………….….______

H = Top of floor to bottom of sliding walk ramp (if applicable)……………...______

N = Frame Thickness: Top of Frame to bottom of Frame………….……….______

Type of Rear door (check one)

Roll-up

Swing

Flip-up

Chassis Dimension Sheet

Truck

Contact Information

Chassis Information


Revision 1.11 - 10 -

5.1 Important Dimensions

Minimum Bed Height dimensions are ALWAYS MAXIMUM LOADED TRUCK.

Maximum Bed Height dimensions are ALWAYS DRY UNLOADED TRUCK.

Application for Walk Ramp is only available for the Bed Heights from 49” to 55”. 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 ILT series liftgate. 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



5.2 Installation Dimensions 900mm arm ILT

Decrease ground clearance only to clear obstructions (i.e. fuel tanks, cross members, hitches, etc.) WITHOUT EXCEEDING MAXIMUM “F” dimension (27”) Mounting Dimensions:

Ground Clearance

"F" Dim.

Mount Clearance End of Body to Front of Mount Plate

Bed Height

Mount Tube

Figure 5-1(Above): 900mm arm ILT

Bed

Height

Ground

Clearence

"F"

Dim. Walkramp Available, 4" sill: Walkramp Available, 5" sill:

47 13

26

x x

48 14 x x

49 15 � x

50 16 � �

51 17

27

� �

52 18 � �

53 19 � �

54 20 � �

55 21 � �

Table 5-1: Suggessted Mounting Dimensions

Application for Walk Ramp is only available for the Bed Heights from 49” to 55”. See section 6.4 for Installation Instructions

1) 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.

2) MOUNT TUBE HEIGHT [F]

• Measure from TOP of Mount Tube to TOP of body floor

3) MOUNT TUBE [K]

• Measure from rear of body to forward edge of Mount Plate.

4) REAR SILL CUT OUT [S]

• Cut-out in rear sill to clear the lift arm

5) GROUND CLEARANCE

• Measure from BOTTOM of Mount Tube to ground



6 Chassis and Body Preparation

Minimum bed height is when truck/trailer is loaded to MAX GVW (all dimensions in inches) F-Dimension, Mounting and Ground Clearance always relate to each other on a set floor height.

NEVER exceed any of the dimensions below. *Use Mount Clearance for pre-install clearance issues (i.e. spring hangers, fuel fills, C/M bolts, etc.) If the F-dimension is increased for a shorter mount clearance dimension, the ground clearance will decrease.

Mounting Dimensions ILT 35" (900 mm) arm, 62" (1600 mm) platform

Bed Height F-Dimension Frame Cut-out

vertical Frame Cut-out

horizontal Mount Clearance Ground

Clearance

47 to 50 26 12 26 38.1 13-16

51 to 55 27 16 25 37.1 17-21 Table 6-1: Installation Dimensions

6.1 Rear Cutout

(Bed Height Ranges: Unloaded Truck 900mm(35½”) Arm)

These Dimensions are starting points. Your final dimensions may vary depending on actual installation F Dimension.

Basic frame cut out and installation information ILT 900mm Arm (35“) 63“ platform. Bed heights covered: 47“-50“ and 51“-55“. Use closest to your applicatioin. The ILT lift gate will require different mounting space requirements depending on floor heights.

Steps:

1. Determine Cutout Dimensions: Determine the correct frame cut out according to your specific bed height

refer to Table 6-1: Installation Dimensions. With long overhang it is even more important to maintain

MIN F-Dim and MAX ground clearance.

2. Trim Frame: Trim rear of truck frame. See Figures 6-2 through 6-4 on the next page.



47"-50"

Assuming 26" F- Dimension

26" 12"

12"

12"

51"-55"

Assuming 27" F- Dimension

16"

25"

2"x3"x3/16" Angle

1/4"x3" HR Flat

Not supplied

Not supplied

900mm(35-1/2")

Figure 6-3: 26“ F- Dimension Cut Out Figure 6-2: 27" F-Dimension Cut Out

Figure 6-1: 900mm Arm

Figure 6-4: Frame Cap



Tack Weld Or ClampTo Rear Sill

Tack or clamp channel to hold in place

Do NOT weld along vertical posts on van install.

3/16" welds for bed extension

Floor at Back & Front EdgeBed Extension Must Be Flush With

Channel or Equiv.

Channel extends 6" beyond end of bed extension for platform installation.

6.2 Bed Extension Installation

Steps:

1. Weld Alignment bars: Tack weld channels or angle (2) to rear sill (not supplied). See Figure 6-5 below.

Figure 6-5: Bed Extension Installation, Side View.

2. Hoist bed extension: Mark the center of the bed extension. Lift the extension until it is flush with the

floor, and center with the truck (Figure 6-5)

3. Secure Bed Extension: Secure the bed extension in place, either with C clamps or proper ground sup-

port.

4. Weld Bed Extension: Verify bed extension is centered on body and flush. Once position has been

checked, Weld as shown in

5. Figure 6-6 below.

6. Bolt on Bed Extension: For Bolt-on applications, refer to section 7.2 on Page 20.

-> 3/16” x 4” welds on approximately 10” centers alternate top and bottom welds

Weld at the 6 positions circled in green below. There are 6 vertical Braces underneath the bed extension. The welds should be madeAbove the location of these braces.Do not weld across the corner posts.

No weldareas

Weld areas (6 total)

Figure 6-6: Bed Extension weld areas



3" Channel

"A"

(Customer Must Miter Per Application)

Channels Shipped W/ Sq. Ends

Note: 20" Bumpers Have Single Step

Interlift 12" Bumpers mayneed notching in some cases

3/16"

3/16"

3/16"

12"

12"

6.3 Dock Bumper Installation (Optional)

This step can be done after the installation of the liftgate. Install dock bumpers (if applicable; available from

PALFINGER Liftgates as an option). Refer to Figure 6-7 below.

Steps:

1. Support Dock Bumpers: Clamp dock bumpers into desired position. Tack Weld the bumper. If bumpers

are bolt on, fasten hardware and DO NOT WELD.

2. Add Supports: Add a diagonal support to the dock bumper, as shown in Figure 6-7 below. Fabrication of

mounts may be required.

3. Weld Bumper: After dimensions have been checked and bumpers are in the desired position, fully weld

the bumpers in the areas shown below.

4. Bolt on Dock Bumpers: For bolt on applications, refer to section 7.2 on Page 20.

Figure 6-7: Bed Height and Dock Bumper Chart



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VIE

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BE

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HD DOCK BUMPER

ILT Heavy Duty Dock bumper for 102” application

Figure6-8: 102“ wide heavy duty dock

bumper steup



6.4 ILT with Walk Ramp (Optional)

Application for Walk Ramp is only available for the LADEN Bed Heights from 49” to 55” as an option. (If no walk ramp setup, disregard this portion of the instruction sheet) ILT Walk Ramp Cradle Installation:

Steps: 1. Set Cradle Height: Set walk ramp cradle to the same level as the walk ramp. To RAISE cradle level: cut

the cradle legs, and then weld in required position. To LOWER cradle level: weld cradle in required po-sition.

2. Weld Cradle: Weld Walk ramp cradle at time of liftgate installation. (The walk ramp cradle will be the new rear support and latch for the walk ramp.) Install the up-stops by welding in place. WELD UP-STOPS 100%.

ALWAYS MOUNT CRADLE AS HIGH AS POSSIBLE. WELD CRADLE 100%.

IMPORTANT! If cradle has been mounted lower, up-stops need to be lowered equally.

CRADLE

UP-STOP

WALKRAMP

ADJUST HEIGHT OF CRADLE TO FIT WALK RAMP.

AFTER CHECKING CRADLE

AND UP-STOP POSITION,

WELD FULLY.

Figure 6-9: Optional Walk Ramp Installation (Top) and Dimensions (Below)

Optimized Dimensions for 4“ Sill Optimized Dimensions for 5“ Sill



7 Gate Installation

7.1 Frame Installation

Never work under platform without safety supports

Note: If installing a bolt on unit, steps are the same, with the exception of welding. Refer to Figure7-4

on page 20.

High heat from welding can damage components. Make sure all components are clear of heat caused by welding. Steps:

1. Hoist Platform: Unfold platform and clamp forklift forks, overhead crane or equivalent to platform. Make

sure the platform is secured safely. Raise lift gate by using forklift, overhead crane or equivalent and

align front edge of platform to back edge of bed extension leaving approx. 3/16” gap.

2. Set F Dimension: Use floor jack or equivalent to swing the frame assembly up to proper “F” dimension

per Figure 7-2. Use second jack to level out under ride guard if necessary. 12 V power supply may be

needed to release pressure on lift cylinder valves.

3. Raise Platform: Raise the platform so that it sits flush with the rear sill/bed extension. Angle adjustment

will come at a later step.

4. Check hardware: Verify that the 2 factory installed bolts at the lower knuckles are secured.

5. Check Up Stops: Verify that the lift arm is firm against both triangle up stops on the underside of the

bed extension (Figure 7-3, next page)

6. Remove Power Pack: Slide out power pack complete from tube before welding.

Abbildung 7-1: Power Pack slid out from tube.



7. Attach Mount Plate: Set mount plates in place and tack weld using 3 fillet welds - 2” long on each side

of mount plate and on top of mount plate. Make sure to connect BODY LONG RAIL to mount plate, if

necessary, extend mount plate with flat bar to reach body.

Figure 7-3: Lift arm attached to the triangle up stops (Shown here in red)

1/4"1/4"

Min. 8" Weld Overlap1/4"

Use second jack to levelUnderride Guard.12 volt power may need to be connected to releasepressure from Lift Cylinders (Down Function)

After welding gate, adjust tip section to be up 2" to 2-1/2" (Refer to Fig 4.2)2.5"

Weld here

90°

Make sure Tube and Frame are in a 90° angle

Figure 7-2: Lift Table and Jack Support



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7.2 Bolt-on setup

Figure7-4: Bolt-on Hole Pattern



7.3 Adjusting the Platform

Steps:

1. Platform Tilt: Adjust the angle of platform when it is flush with the rear sill of the truck. To tilt the plat-

form like shown in Figure 7-2. Shim up the block on both shackles. If you need to lower the angle,

grind down the block on the shackles like shown in Figure 7-5. Operator must continue to hold down

button/toggle after lift arms touch ground to allow platform tip to tilt to the ground

2. Remove Retaining Bolts: Remove factory installed retaining bolts from lower lift cylinder knuckle

(Figure 7-6)

PLATFORM WILL NOT TILT TO THE GROUND IF THESE BOLTS ARE NOT REMOVED!

TO RAISE OR LOWERPLATFORM ANGLE,

WELD IN SHIM MATERIALOR

GRIND OFF MATERIAL ATMATING SURFACE.

Figure 7-5: Platform Angle Adjustment

Remove bolts from both swing arms. Swing arm is able to swingwhen platform touches groundwith bolts removed.

Remove the bolts that are underneath the frameand attached to the bottom of the swing armsnear to the end of lift cylinders.

Figure 7-6: Remove Knuckle bolts



3. Reorient Torsion Spring: The torsion springs that assist the folding of the gate are shipped with no ten-

sion to aid the installation process. The dashed lines in Figure 7-7 show the shipping position of the

spring arm. Fold up the platform and lower the gate to within 2” of the ground. Flip over the platform in-

to stored position, in order to remove load from the pin lock bolt.

Platform is heavy. Use caution while handling.

• Remove parallel arm retaining bolt and partially slide the pin toward the center of the platform far

enough to reorient the platform torsion spring leg to the rear side of the pin. Install the spring

retaining clip as shown in red.

• Slide the parallel arm pin back into with alignment pin in the hole provided in the shackle.

• Install and torque the pin lock bolt and torque to 14 ft-lb

• Repeat for second platform spring

7.4 Final steps of installation

Steps:

1. Battery Connect: Connect battery cable to truck battery, aux battery or temporary battery

(Refer to chapter 8 Electrical Installation)

2. Cycle Gate: Cycle gate several times to assure proper alignment.

Do not power gate hard against bed extension while gate is only tack welded in po-sition. 3. Weld Gate: Complete welding of gate. Weld all contact areas 100% with ¼” fillet welds.

4. Adjust Sliding Wheel: Adjust sliding wheel bracket so the platform is approximately 5 to 10

degrees in from vertical when resting against the wheel. (Figure 7-9 below)

Figure 7-7:Torsion Spring Setting Spring arm must be secured in retainer

as shown here.

Spring Retaining Clip



Loosen bolts and slide to acheive 5°-10°.

Verify platform will lowerwithout hang up before welding.Slide tube slightly if platform does not lower smoothly.

5°-10°

Set angle cap to contactplatform when closed. Adjust(2) rubber snubbers to raise tight against frame caps

Figure 7-9:Cap as platform stop

5. Frame Caps: Double check frame caps (Figure 7-9). Reference chapter 5.2.

6. Adjust Snubbers: Adjust (4) rubber snubbers up to force platform against frame caps to hold platform

from bouncing while vehicle is moving. Also make sure the rubber snubbers are adjusted so that the

gate does not rub on other components during the opening and closing sequences. Alternative store

stop method is shown on the next page (Figure 7-10)

Figure7-8: Fold over wheel adjustment



Use alternative platform store stop method only on installation with square cut frames.

Weld to chassisand/orlong sill

3" Std channel

Set channel to contactplatform when closed. Adjust(4) rubber snubbers to raise tight against channel

Figure 7-10: Alternate frame modification

7. Adjust Spring Assist: To change the amount of platform spring assist, pull the platform from under the

truck to vertical position. Rotate the tension block so that the short arm of the spring is just making con-

tact against one side of the block. This will ensure that the operator is not pulling against the spring to

deploy the platform and provides correct tension for lifting the platform. Each position of the block will

put a different tension on the spring, and make it heavier or lighter when closing the gate (Please see

Figure 7-11).

Rotate this block if needed for additional fold up assist.Each position on the block will put a different tensionon the spring.

Afer adjusting the block,make sure to tighten its nut and bolt.

Figure 7-11: Rotate block to adjust platform spring tension



150 AMP Resetable Breaker

RES

ET

Test

8 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, fuel lines, etc. It is recommended to use dielectric grease on all electrical connections.

8.1 Main Power Connections

Steps:

1. Install and Secure Cable: Install the 2 Ga. battery cable securely from pump/motor box to battery. Se-

cure the cable every 12 inches. Heat shrink lug connection to cable.

2. Check Connections: Assure all connections are tight and securely fastened.

Recommended Cable Routing for Trucks

Body Stringer

Sub Wood

Truck Frame

Cable Staples

Route Cables to OUTSIDE of U-Bolts

For trailer installation refer to trailermanufacturers recommended routing

Battery Cable

2 Wire Control Box Power Cable

4-Wire Control Cable

Figure 8-1: Reccommended Cable Routing for Trucks

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.

8.2 Circuit Breaker

Steps:

1. Mount Circuit Breaker: Mount circuit breaker securely in battery box or on top of battery.

2. Connect Wires: Connect lift gate 2 Ga. cable to stud on circuit breaker. Connect 2 Ga. jumper from

open stud on breaker to positive battery post

3. Optional: Copper buss bar at battery

post to circuit breaker



Rear Vertical Body Post

Switch

# 8 x 1-1/2" Pan Head

MBB

DO NOT use impact,power drill or power driverto torque screws tight

SCREWS MUST BEHAND TIGHTENED

24"approx.

ø 7/8"

8.3 UP/DOWN Switch Installation

Determine location for fixed toggle switch on corner post in a way that the operator can view the platform and surrounding areas while operating the lift gate. Place toggle switch in a hori-zontal position Steps: Roll Up Doors (Figure 8-2)

1. Route Wire: Locate area on rear curb side post of body where switch can be reached by operator from

ground and body floor. Approximately 24” up from truck floor. Drill 7/8” hole for control wire. Disconnect

all (3) connectors from up/down control switch wire. Route wire through rear post and back to pump &

motor box.

2. Reconnect wire: Reconnect control switch wires from step 1 above.

3. Mount Switch: Attach switch, using 2ea. #8x1-1/2” self-tapping screws. Switch is shown below in Figure

8-2.

4. Check Wire Clearance: Verify wire is clear of all moving parts and securely tied up.

5. Check Switch Operation: Check that the up function operates with switch up on your installation. Swap

#1 & #2 wires in pump & motor box to correct if necessary.

6. Cover Connetions: Heat shrink or protect all connections.

Figure 8-2: Roll Up Door switch placement



Typical Trailer On/Off Installation

Corner Post

Switch

MBB

Stake bed and Swing Doors (when no space at corner post) (Figure 8-3) 1. Route Wire: Locate Area under bed extension or under body that will not be obstructed by doors when

open. Drill 7/8” hole for control wire. Disconnect all (3) connectors from up/down control switch wire.

Route wire through rear post and back to pump & motor box


3. Mount Switch: Attach switch, using 2ea. #8x1-1/2” self-tapping screws or for switch cup use 3 #12

sheet metal screws.


5. Check Switch Operation: Check that the up function operates with switch up on your installation. Swap

#1 & #2 wires in pump & motor box to correct if necessary.


Figure 8-3: Passenger side view of Swing door switch installation



8.4 ON/OFF Switch

Liftgate Cab Cut Off Switch MUST be installed and in clear view of driver.

Shut Off

Place cab cut off switch (if applicable) in clear view of the driver and within reachfrom the ground

Figure 8-4: On/Off switch in Cab

Steps:

1. Disconnect Control Wire: Disconnect (2) connectors from on/off control wire

2. Mount Switch: Install Liftgate Cab On-Off Switch in truck dashboard or at rear of trailer in clear view of

driver (Figure 8-4)

3. Route Wire: Route and secure the control wire cable every 12 inches against the frame with frame clips

or equivalent along the frame to pump & motor box.




Inspect and test all electrical connections, wiring and the different functions to make

sure that the electrical installation is complete.

8.5 Remote Hand Control Installation (Optional)

1. Determine Wire Connections: Locate existing wire on gate for control switch and determine where they

are connected to.

2. Connect Wires: Slide heat shrink onto hand control wire and connect wires to matching numbers from

hand control cord to lift gate wire � test functions.

3. Crimp & cover Wires: Crimp connectors and heat shrink connections

4. Install Holster: Mount holster on truck/trailer.

2 Button Hand Control

UP - Solenoid - 5 - RED

DOWN - Release valves - 6 - YELLOW

12V HOT - On-off switch - 4 - GREEN



Circuit breaker MUST be fastened securely

Gro

und C

able

Ground

(Second Battery Shownfor heavy applications Only)

+-

Liftgate Mount FrameMain Truck Batteries

2 G

a. Lift

gate

Pow

er

Cable

Ground

+-

+ -

To Ignition Switch

Ground

Aux. Batteries (if applicable)

BatteryIsolator

+ -

(if applicable)

CircuitBreaker

MainDisconnect

(ifapplicable)

8.6 Wiring Diagram (Main battery wiring)

FOLLOW DOTTED LINE IF ISOLATOR OR AUXILLIARY BATTERIES INSTALLED!

Figure 8-5: Main Wiring



8.7 Wiring Diagram (Gravity Down)

Figure 8-6: Electrical Wiring overview



3/2

/11

Jones

30 F

t. x

2 g

a. B

attery

Cable

Power - #4 Black

Starter - #5 Black

Lower - #6 Black

Gro

und -

Low

er

Sole

noid

- B

lack

Sta

rter

Sole

noid

Toggle

Control S

witc

h

2 g

a.

Gro

und C

able

Ele

ctric

Moto

r

ILT P

D - W

irin

g S

chem

atic

1"=

1"

INTERLIFT, Inc.

15939 Piuma Ave.

Cerritos, CA 90703

888-774-5844

150 a

mp

Circu

it B

reake

r

Rais

e

Pow

er

Dow

n

10 A Fuse

Pow

er

- B

lack

Cab S

hut-O

ffM

ain

Lift

gate

Power - Brown

Load - Blue

12 v

olt

pow

er

supply

Gro

und -

Low

er

Sole

noid

- B

lack

Shift

Sole

noid

- Y

ello

w

Low

er

Sole

noid

- B

lack

Ground - Yellow

Shift

Valv

eS

5

Low

er

Valv

eS

1Low

er

Valv

eS

2

Toggle

contr

ol -

Buch

er

Pum

p -

Full

Tim

e P

ow

er

Dow

n

Low

er

Sole

noid

- B

lack

MB

B

Power Down Harnesswith Diode

EC

N-M

0218 -

5/1

0/1

3 -

Rev

"C"

Added n

ew

Cab S

hut-

Off S

witc

h

EC

N1929 -

7/8

/11 -

Rev

"B"

Added n

ew

PD

harn

ess

EC

N1771 -

3/2

2/1

1 -

Rev

"A"

Rele

ase

d to P

roduct

ion

70-1

011

-900

56

S1

S5

Pow

er

Gro

und

Load

Ground - Yellow/Green

Spade C

onnect

ors

with

housi

ng

8.8 Wiring Diagram (Power down )

Figure 8-7: Wireing Schematic (Power Down) After liftgate s/n PT-10598



3/2

/11

Jones

30 F

t. x

2 g

a. B

attery

Cable

Power - #4 Black

Starter - #5 Black

Lower - #6 Black

Gro

und -

Low

er

Sole

noid

- B

lack

Sta

rter

Sole

noid

Toggle

Contr

ol S

witc

h

2 g

a.

Gro

und C

able

Ele

ctric

Moto

r

ILT P

D -

Wirin

g S

chem

atic

1"=

1"

INTERLIFT, Inc.

15939 Piuma Ave.

Cerritos, CA 90703

888-774-5844

150 a

mp

Circu

it B

reake

r

Rais

e

Pow

er

Dow

n

10 A Fuse

Pow

er

- B

lack

Cab S

hut-O

ff

Not use

d

Main

Lift

gate

Power - Brown

Power - Blue

12 v

olt

pow

er

supply

Gro

und -

Low

er

Sole

noid

- B

lack

Shift

Sole

noid

- Y

ello

w

Low

er

Sole

noid

- B

lack

Ground - Yellow

Shift

Valv

eS

5

Low

er

Valv

eS

1Low

er

Valv

eS

2

Dio

de C

ove

r

Toggle

contr

ol -

Buch

er

Pum

p -

Full

Tim

e P

ow

er

Dow

n

Low

er

Sole

noid

- B

lack

MB

B

Power Down Harness with Diode

EC

N1771 -

3/2

2/1

1 -

Rev

"A"

Rele

ase

d to P

roduct

ion

70-1

011

-900

Figure 8-8:Wireing schematic (Power Down) DISCONTINUED on liftgate s/n PT-10598



9 Lubrication and Final Inspection

Steps:

1. Grease Platform Joints: Open platform and raise lift gate to bed level. Remove red caps, apply grease

until grease begins to flow from bushing ends. Lower platform to ground and repeat. Fold platform onto

wheel and grease platform pins again. Reference Figure 9-1 on the following page to see grease

points.

2. Cycle Platform: Cycle platform open and closed several times and grease again (see Figure 9-1 on the

next page)

3. Clean and Cap Off: Wipe excess grease from joints and replace ALL red caps

4. Check Hardware: Check ALL pin lock bolts for proper torque of 14 ft-lbs

5. Paint: Paint all welded areas and area that have been scratched during installation. Remove any over-

spray from cylinder shafts

Note: Do not paint plastic wheel or chrome hydraulic shafts

6. Check Wires & Hoses: Ensure that ALL hydraulic lines are secured properly; Check for any wires

or hoses that may rub during operation. Re-route and/or tie up as necessary. Double check that

there are NO kinks in any hydraulic lines.

7. Check Hydraulic Fluid Level: Lower platform completely to ground. Pull out pump & motor tray and

check oil level with platform on ground

8. Apply Decals: Install all operation and safety decals



Grease Points mirrored on curb side. (16 Total)

Figure 9-1: Grease Points



Functions:

Lift: MLower: S1+S2

Pressure Relief

2850 PSI200 bar

Restrictor Valve R5

Flow Divider

Functions:

S1 and S2 = Release Valve for lowering functionR1 and R2 = Flow Restrictor located inside hose adaptor on lift cylinderR5 = Restrictor Valve located in power packFlow Divider is activated, when fluid is going back into the power packIf Flow Divider is loose or hanging up the fluid is circulated back in to tank

Access for pressure gauge

Datum

01.08.08

Hydraulic Schematic

HACKBARTH

2 cylinder lift gate

Hydraulic Schematic (Gravity Down)

Figure 9-2: Hydraulic schematic, Gravity Down



Low

er

= S

1 +

S2

S5 -

Shift

Valv

e is

NO

T a

ctiv

ate

d for

Gra

vity

Dow

n funct

ion.

Gra

vity

Dow

n n

eeds

a d

irect

open p

ath

to tank

for

oil

suct

ion.

Port

ILT P

ow

er

Dow

nU

SA

Hyd

raulic

Sch

em

atic

1"=

1"

INTERLIFT, Inc.

15939 Piuma Ave.

Cerritos, CA 90703

888-774-5844

Jones

4/1

0/1

1

Pum

p U

nit

M-3

441-0

104

Relie

f V

alv

e2850 p

si

Filt

er

Pum

p

Rese

rvoir T

ank

Moto

r

Bre

ath

er

S5 S

hift

Valv

e

"A"

"B"

R1

R2

S1

S2

Lift

Cyl

inder

Lift

Cyl

inder

S1 &

S2 -

Rele

ase

Valv

e for

Low

ering

R1 &

R2 -

Flo

w R

est

rict

or

for

limiti

ng lo

wer

speed.

S5 -

Shift

Valv

e is

act

ivate

d u

pon P

ow

er

Dow

n funct

ion o

nly

.

Pilo

t to

clo

se c

heck

direct

s oil

back

to tank

on G

ravi

ty D

ow

n.

Rais

e =

MP

ow

er

Dow

n =

M +

S1 +

S2 +

S5

M

80-1

011

-901

Pilo

t to

Clo

seC

heck

Valv

e

2 P

osi

tion

4 w

ay

Valv

eS

5 -

Shift

Valv

e is

NO

T a

ctiv

ate

d for

Rais

e funct

ion.

Buch

er

Pum

pw

ith C

heck

Valv

e

Use

d for

"Full

Tim

e"

& "

On-C

om

mand"

Pow

er

Dow

n

EC

N1929 -

7/8

/11 -

Rev

"A"

Rele

ase

d to p

roduct

ion

9.1 Hydraulic Schematic (Power down)

Figure 9-3: Hydraulic Schematic, Power Down version after s/n 10598



Port

ILT P

ow

er

Dow

nU

SA

Hyd

raulic

Sch

em

atic

1"=

1"

INTERLIFT, Inc.

15939 Piuma Ave.

Cerritos, CA 90703

888-774-5844

Jones

10/1

5/1

0

Pum

p U

nit

Relie

f V

alv

e2850 p

si

Filt

er

Pum

p

Rese

rvoir T

ank

Moto

r

Bre

ath

er

S5 S

hift

Valv

e

"A"

"B"

R1

R2

S1

S2

Lift

Cyl

inder

Lift

Cyl

inder

S1 &

S2 -

Rele

ase

Valv

e for

Low

ering

R1 &

R2 -

Flo

w R

est

rict

or

for

limiti

ng lo

wer

speed.

S5 -

Shift

Valv

e is

act

ivate

d u

pon L

OW

ER

funct

ion o

nly

.

Pilo

t to

clo

se c

heck

valv

e is

NO

T u

sed o

n full

time P

D.

Rais

e =

MP

ow

er

Dow

n =

M +

S1&

2 +

S5

M

Pilo

t to

Clo

seC

heck

Valv

e

2 P

osi

tion

4 w

ay

Valv

e

Buch

er

Pum

p w

ith N

O c

heck

Valv

e

Full

time P

ow

er

Dow

n O

NLY

MB

B T

oggle

Control

EC

N1929 -

7/8

/11 -

Rev

"B"

Added s

/n r

ange for

liftg

ate

s

EC

N1771 -

3/2

2/1

1 -

Rev

"A"

Rele

ase

d to P

roduct

ion

80-1

011

-900

Dis

contin

ued o

n li

ftgate

s/n

PT-1

0598

Figure 9-4: Hydraulic Schematic, Power Down version (Discontinued on s/n PT-10598)



9.2 Decal Placement and Inspection

For operator’s safety, all decals appearing in “Decal Kit” must be placed visibly on con-trol side of liftgate to be read by operator. This is typically a combination of decals on the lift-gate and truck body. Please make sure to place the maximum capacity decal (D) on driver and curb side.

(A) 1 ATG-URGWA - Urgent warning: Elevating gate instructions

(B) 1 ATG-ILR-ILFS - Operational 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)

(J1) 1 ATG-UD - Toggle Decal OR (J2) 1 ATG-SWILMDC - Operational Instructions for Hand Control

(K) 1 ATG-WNG - Warning: Use handle to open (must be located underneath handle (main section))

(L) 1 ATG-ILTLUB - Lubrication and Fluid Points

(M) Conspicuity Tape (If applicable)

Decal - A

Decal - B

Decal - C

Decal - D

Decal - H

Decal - E

Decal - F

Decal - G

Decal - K

Decal - L

Decal – J2

(PowerDown)

Decal – J1

Decal - M



It is the installer’s responsibility to determine the proper application of the Conspicuity tape, and to ensure that the vehicle or trailer meets DOT and federal lighting regulations. Keep in mind that there are different requirements depending on the classification of the vehicle or trailer. Placement of decal “M“ shown below is an example of conspicuity tape placement.

Decal J

Decal F

Decal G

Decal D

Decal B

Decal E

Decal A

Decal L

Decal C - By circuit breaker at batteries Decal H - In the cab or at On - Off at rear

Decal K

Figure 9-5: Decal Placement Guidline

Decal M



H Dimension: 15”< H 60” from ground to center of tape

Requirement 3: Red/white reflective tape applied across the entire width of the rear underride protection device. Note: Not required if no underride protection is equipped

Requirement 2: On each corner: Two 12” long white reflective pieces, placed adjacently to one another as close to the upper corner of the trailer as possible

Requirement 1: Red/white reflective tape alpplied across the entire width of the trailer placed at an appropriate height H from the ground

H

It is the installer’s responsibility to determine the proper application of the Conspicuity tape, and to ensure that the vehicle or trailer meets DOT and federal lighting regulations. The following diagram is a guideline for placement on trailers over 80” wide and GVWR of 10,000 Lbs or more. This document is not intended to replace published agency regulations, and it is strongly recommended that the installer refer to the Code of Federal Regulations (CFR) which can be viewed at http://ECFR.gpoaccess.gov.



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

� 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 1.5" from top when cylinders are completly compressed (platform is resting on the ground).

� Hydraulic components and connections do not leak. (Should be checked after unit is hydraulically locked for five (5) minutes.)

� All hydraulic lines are secured with cable ties, hoses clamps, or other fasteners. No hoses or components rub on the frame, platform, or any other components while unit is in operation or in storage. No hoses are kinked or bent. Electrical Inspection

� Battery cable(s) attached and clamped tight and dielectric grease is used to seal all connections.

� All electrical lines are secured with cable ties, hoses clamps, or other fasteners and are properly protected.

� Circuit Breakers installed and wired per instructions.

� Lights wired properly and operate per DOT, State, and Federal requirements. Operational Inspection

� All decals are in place and legible per instructions.

� All pivot points are lubricated per instructions, and Zerk fittings have been capped.

� Up stops are in place. Wheel is set for proper opening when lowering. Coil springs at platform are adjusted.Platform torsion rod is adjusted. Snubber pads are tight against platform. Bolts are removed from Auto Tilt Knuckles.

� Platform travels up and down smoothly and freely, without any hesitation or unusual noises.

� Platform is flush with the bed extension, tip is pitched approximately 2“-2.5“ above rear bed extension when raised completely.

� Platform rests on the ground evenly when lowered completely.

� Platform raises and lowers properly and at correct speed. (2 to 4 inches per second)

� Gate is painted, body is clean around gate. Cylinders are clean and rubber & plastic caps are in place.

� The liftgate serial number and model number are documented on the inside of the front cover of the Owners Manual, as well as the installation manual in the space provided.

� Owners Manual is in the vehicle's glove box.

� Supervisor has demonstrated the instructions in the Owners Manual to the customer/driver upon delivery. Inspection Information: Name (please print): ____________________________________________________________ Completed by: _________________________________________________________________

(signature)

Title: ______________________________________________ Date: ______________________

Documents

ILT / ILT-WR / ILT-PD