INTERLIFT - Palfinger · 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

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 Fax (562)-924-8318

572 Whitehead Road, Trenton, NJ 08619 Tel (609)-587-4200 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

Revision 1.7 Page 2

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

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

7 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 Page 3

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 Page 4

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 Page 5

3 Tools for Installation

Metric Wrench Set

Basic Screwdriver Set Pliers Wire Crimp Pliers

Test Light

Snap Ring Pliers Hammer Metric Allen Set 1.5mm-10mm

½” Impact & Sockets

Sm. Metric Socket Set Assorted Drill Bits Floor Jack or Equiv.

Sm. To Med. Bottle Jack

Forklift or O/H Crane Hand Held Grinder Paint Gun

Pry Bar

3/8 Drill Motor Heat Gun or Equiv.

Min. 250 Amp Welder

Cutting Torch or Equiv.


Revision 1.7 Page 6

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 Page 7

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.

Bed Level

10"

12"74-1/2"

58" Max.15-1/4"

Bed Height Chart

Platform Size Dock Loading Bed Height Range

Min. Max.

NO Dock Loading Bed Height Range

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 Page 8

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.

Z

Z

Y

Y

X

X

Side Wall Requirements Chart

ILD35 ILD44 ILD55 ILD66

X=Side Wall Tension 1900 lbs. 2400 lbs. 2950 lbs. 3500 lbs.

Y=Side Wall Compression 1900 lbs. 2400 lbs. 2950 lbs. 3500 lbs.

Z=Side Wall Shear 2700 lbs. 3100 lbs. 3800 lbs. 4300 lbs.


Revision 1.7 Page 9

Step 4 Determine liftgate width requirements The ILD series liftgate is offered in two standard widths for 96” and 102” wide bodies.

Bed Height

Inside Frame Width

Outside Frame Width

15-1/4"

74-1/2"

Nominal Truck or Trailer Width

Liftgate Outside Frame

Liftgate Inside Frame

Liftgate Platform Width

96” Wide Body 94” 84” 80”

102” Wide Body 100” 90” 86”


Revision 1.7 Page 10

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 LevelRear Sill

Rear BumperNeeds to be mounted Flush with Sill.

Rear Sill

Bed LevelRear Sill

90°

Rear BumperFlush with sill.



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 LevelRear Sill

Hitch or other Equipment must NOTextend rearward of rear sill.



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.

Bed Level Corner Stiffener

Light Box

Corner Post

Liftgate Mounting Surface

Liftgate Platform Surface

Gap between Sill and Liftgate

Corner Post

Sub-Frame

Liftgate

Corner Post

Sub-Frame Flat Bar

Liftgate

Tubing sub-frame Flat Bar sub-frame



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.

Corner Stiffener

Corner Stiffener

Flat Bar

Flat Bar

Flat Bar



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.

72"

Approx. 60"

Support Bar1/4" x 3" Min. Flat Bar

1/4" x 100% weld each end

Sub-plate for alum side rails1/4" x 4" Min. bolted either side

of body cross member.



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.

Bed Height Support Channel

Remove Hydraulic enclosure



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.

Bed Level

Forklift not shown

Bed Height Support Channel

4x4x24 Wood block

Forklift forks

90°



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! 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.

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”.

Traverse

Traverse bolts

After install, lower traverse to be level with vehicle floor.

Vehicle Floor Height

Traverse Floor Height

Figure. 1 Initial install



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 "B"

Dim "D"Dim "C"

Square



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

¼” x 100% Weld Dock Bumper Only

Keep this area clear of welds – Danger of burning the switch



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.





IMPORTANT !

ADDENDUM TO WELDING INSTRUCTIONS



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



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.



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.



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 C B A

A 3/8” Lift Cylinder up hose

B 3/8” Lift Cylinder down hose

D ¼” Open- Close Cylinder OPEN hose

C ¼” Open- Close Cylinder CLOSE hose

D C B A

A

C D

Battery- and Power Pack Box Curb Side of Liftgate



7.4 Hydraulic Schematics (1st, 2nd and 3rd Generation pump setup)

1st Generation Pump setup



2nd Generation Pump setup



3rd Generation Pump setup



The following drawing shows where the different function valves can be physically found.

Prefilled hydraulic oil and specification sheet

Hydraulic Fluid Installed at Factory:

ARCTIC FLO

Typical Physical Specifications:

Gravity, API 30.4

Pour Pt. ºF <-85

Flash Pt. ºF C.O.C. 320

Viscosity:

SUS @210ºF 41.6

SUS@ 100ºF 97

cST @ 100ºC 4.65

cST @ 40ºC 19.66

Viscosity Index 172

(Hours to 2. Neut.NO.) 2500

Main pump & motor setup with operating valves



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.

Control Power 4-Wire CableTruck Application-Always wire to truck batteryTrailer Application-wire to aux. battery

+ -

20 AmpIn-LineFuse

+ -

Wires marked#2;#4 (Black)go to hot,#1 and green/yellowgo to ground

PC-board

2 27

15 Amp fuses

J1 Plug

#2 #4+ +E E- -

gr/ye #1

J2 Plug

Optional:Main power on/off switch



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.

Clamp Bar

Nut & Washer

Mounting Bolts

Positive Terminal To Right Side



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.

ChargingCircuit BreakerAuto Reset

Starter Solenoid 1

Motor 1

Master Shut OffSwitch

Ground to Chassis

Ground to Chassis

Truck Batteries

Box GroundTreminal

Truck Kit - Single Pump

24"

50"

36"

11"

50"

40 ft

MotorCircuit Breakers

Flag Reset




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.


Starter Solenoid 2

Starter Solenoid 1Motor 2

Motor 112v Battery



Flag Reset

Ground to Chassis

Ground to Chassis

Truck Batteries

Box GroundTreminal


Starter Solenoid 1

Motor 112v Battery


Ground to Chassis

Ground to Chassis

Truck Batteries

Box GroundTreminal

Truck Kit - Single Pump - Aux Battery

Truck Kit - Dual Pump - Aux Battery

MotorCircuit Breaker

Flag Reset

40 ft

24"

50"

36"

11"

50"

11"

11"

36"

40 ft

24"

36"

36"

11"

50"

11"

11"

36"

24"

36"

36"

Circuit BreakerFlag Reset

OptionalIsolator

Solenoid

Circuit BreakerFlag Reset

OptionalIsolator

Solenoid




Starter Solenoid 2

Starter Solenoid 1Motor 2

Motor 112v Battery

Ground to TrailerSide Rail


Box GroundTreminal


Starter Solenoid 1

Motor 112v Battery

Ground to TrailerSide Rail


Trailer Kit - Single Pump - Aux Battery

Box GroundTreminal

Trailer Kit - Dual Pump - Aux Battery

Trailer SocketSingle & Dual Pole


Flag Reset


Flag Reset

40 ft

24"

50"

36"

11"

50"

11"

11"

36"

40 ft

24"

36"

36"

11"

50"

11"

11"

36"

24"

36"

36"

40 ft

40 ft

Trailer SocketSingle & Dual Pole

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.



7.4 Trailer to Tractor Ground TEST

Testing of full system using a battery load tester:

Start with testing each individual battery on both tractor and trailer before procedingto 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 tractorwill not show insufficient connections or ground problems

CROSS TEST ON ENTIRE CHARGE SYSTEMSINGLE POLE PLUG SET UP

b

d

a 12 Volt lead from tractor coil cordb Center (+) plug on front of trailerc Trailer ground on front of trailerd Tractor chassis ground

cb

cb

a

cc



7.5 Schematic (Electrical)

ILD

Plu

s

V

olt

Gauge



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.



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 - A

Decal - B

Decal - C Decal - D

Decal - E

Decal - G

Decal - H

Decal - F

Decal - K Decal - J



Step 1 Decals are adhered in a conspicuous place near main controls as shown below.

Decal E

Decal A

Decal B Decal H

Decal C

Decal F

Decal G

Decal D

Decal J

Decal J



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

Travel Lock



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.

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).

Open/Close Button Down / Lower Button

Down / Lower Button



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.

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

UP / Raise Button

Open/Close Button



Step 7 Using the “DOWN” button, push down twice (within 3 seconds) and power down platform past the Travel Locks. (See Illustration)

Step 8 Using the “UP” button, raise platform up until travel ears clear the travel lock slot.(See Illustration)

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

Down / Lower Button

Up / Raise Button



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: _____________________

Documents

INTERLIFT - Palfinger · 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