ilt / ilt-wr / ilt-pd · minimum bed height dimensions are always maximum loaded truck. maximum bed...
TRANSCRIPT
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.)
ILT Installation Manual Chapter 2
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.
ILT Installation Manual Chapter 2
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
ILT Installation Manual Chapter 3
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
ILT Installation Manual Chapter 4
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
ILT Installation Manual Chapter 4
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
HYDRAULIC POWER UNIT
(inside tube)
PLATFORM TIP CART STOPS (optional)
SINGLE ACTION
LIFT CYLINDERS
ILT Installation Manual Chapter 4
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
HYDRAULIC POWER UNIT
(inside tube)
BUMPER
PLATFORM TIP
ILT Installation Manual Chapter 5
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
ILT Installation Manual Chapter 5
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
ILT Installation Manual Chapter 5
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
ILT Installation Manual Chapter 5
Revision 1.11 - 11 -
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
ILT Installation Manual Chapter 6
Revision 1.11 - 12 -
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.
ILT Installation Manual Chapter 6
Revision 1.11 - 13 -
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
ILT Installation Manual Chapter 6
Revision 1.11 - 14 -
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
ILT Installation Manual Chapter 6
Revision 1.11 - 15 -
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
ILT Installation Manual Chapter 6
Revision 1.11 - 16 -
Top s
urf
ace
of B
ed E
xtensi
on w
ill b
eflu
sh w
ith top s
urf
ace
of D
ock
Bum
per.
ILT H
eavy
Duty
Dock
Bum
per
Inst
alla
tion
Ple
ase
Note
: T
he h
eavy
Duty
Bum
pers
can o
nly
be u
sed o
n a
102"
wid
e v
ehic
le w
ith ILT
.
BE
D E
XT
EN
SIO
N
BE
D E
XT
EN
SIO
N
4/2
6/1
2
TO
PV
IEW
RE
AR
VIE
W
95"
(refe
rence
)
BE
D E
XTE
NS
ION
HD DOCK BUMPER
ILT Heavy Duty Dock bumper for 102” application
Figure6-8: 102“ wide heavy duty dock
bumper steup
ILT Installation Manual Chapter 6
Revision 1.11 - 17 -
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
ILT Installation Manual Chapter 7
Revision 1.11 - 18 -
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.
ILT Installation Manual Chapter 7
Revision 1.11 - 19 -
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
ILT Installation Manual Chapter 7
Revision 1.11 - 20 -
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14.00"
24.00"
29.00"
34.00"
46.50"
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- 13 for
Bed E
xte
nsio
n-
16 for
Mount P
late
s-
26 for
Dock B
um
pers
3.00"
2.50"
2.50"
7.2 Bolt-on setup
Figure7-4: Bolt-on Hole Pattern
ILT Installation Manual Chapter 7
Revision 1.11 - 21 -
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
ILT Installation Manual Chapter 7
Revision 1.11 - 22 -
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
ILT Installation Manual Chapter 7
Revision 1.11 - 23 -
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
ILT Installation Manual Chapter 7
Revision 1.11 - 24 -
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
ILT Installation Manual Chapter 8
Revision 1.11 - 25 -
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
ILT Installation Manual Chapter 8
Revision 1.11 - 26 -
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
ILT Installation Manual Chapter 8
Revision 1.11 - 27 -
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
2. Reconnect wire: Reconnect control switch wires from step 1 above.
3. Mount Switch: Attach switch, using 2ea. #8x1-1/2” self-tapping screws or for switch cup use 3 #12
sheet metal screws.
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 8-3: Passenger side view of Swing door switch installation
ILT Installation Manual Chapter 8
Revision 1.11 - 28 -
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.
4. Reconnect wire: Reconnect control switch wires from step 1 above.
5. Check Wire Clearance: Verify wire is clear of all moving parts and securely tied up.
6. Cover Connetions: Heat shrink or protect all connections.
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
ILT Installation Manual Chapter 8
Revision 1.11 - 29 -
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
ILT Installation Manual Chapter 8
Revision 1.11 - 30 -
8.7 Wiring Diagram (Gravity Down)
Figure 8-6: Electrical Wiring overview
ILT Installation Manual Chapter 8
Revision 1.11 - 31 -
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
ILT Installation Manual Chapter 8
Revision 1.11 - 32 -
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
ILT Installation Manual Chapter 9
Revision 1.11 - 33 -
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
ILT Installation Manual Chapter 9
Revision 1.11 - 34 -
Grease Points mirrored on curb side. (16 Total)
Figure 9-1: Grease Points
ILT Installation Manual Chapter 9
Revision 1.11 - 35 -
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
ILT Installation Manual Chapter 9
Revision 1.11 - 36 -
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
ILT Installation Manual Chapter 9
Revision 1.11 - 37 -
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)
ILT Installation Manual Chapter 9
Revision 1.11 - 38 -
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
ILT Installation Manual Chapter 9
Revision 1.11 - 39 -
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
ILT Installation Manual Chapter 9
Revision 1.11 - 40 -
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.
ILT Installation Manual Chapter 10
Revision 1.11 - 41 -
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: ______________________