ILD TROUBLE SHOOTING & PARTS Interlift Inc.a member of MBB

ILD

TROUBLE SHOOTING & PARTS

Interlift Inc.a member of MBB 15939 Piuma Ave, Cerritos, CA 90703 TEL.( 888) 774-5844 Fax. (562) 924-8318

DATE:REVISION:

S
ILD FREQUENTLY ASKED QUESTION
Most Common Problems

Possible Cause Remedy

Cylinder making a squealing noise when platform is raised and lowered

Seals on the lifting cylinders are tight

Use Caterpillar additive. Start with 2 ounces, cycle liftgate 4-5 times. Add two ounces more at a time until noise stops. Max 8 ounces. If after 8 ounces the noise does not stop or diminish contact factory.

Cylinder making a squealing noise when platform is lowered only, with our without load.

Pressure to high on down Cycle

Lower the pressure on the down cycle to 500 psi or lower if necessary

Change the pressure compensating flow valve if reducing the down pressure does not work

Liftgate will raise but not lower or lowers slower than normal

Down valve getting less than 10 vdc when switch activated.

Test that batteries supplying power are fully charged and have reserve capacity. If not replace them

Power to coil but coil not magnetized. When power is on the coil a screw driver on the end of the valve will be pulled in like a magnet.

Replace Coil and Valve.

Coil is magnetized but valve not opening

Replace Coil and Valve

No power to coil Replace wire, switch or both after determining where the fault is.

Platform opens to slow

Orifice in the hydraulic close cylinder is blocked

Remove hoses at the hydraulic close cylinder, remove fitting on the hydraulic close cylinder and clean using a drill bit no larger than 1/64” in diameter.

Platform will not lock properly on both sides

Leaking cylinder on one side

Power platform all the way to the floor of the truck to re level it then lower it back into the locks.

Not enough oil in tank Test oil with platform at floor height

Add oil, Shipped with “America’s Choice Hydraulics RO-AW-LT32-ISO NG32. Alternative oils recommended are Dextron, automatic transmission fluid or Aircraft hydraulic fluid

Platform leaks Down More than 1” overnight

Is it the Right Side Replace cylinder on that side. Usually if the Right side leaks, the left side will hold firm. It may move slightly but not very much.

Is it the Left Side If the Left side comes down with the right side coming down much less, replace the LH cylinder

Both sides leak down evenly

Lock valve is defective, replace lock valve, ensure when lock valve is removed that no contamination is found in the valve.

If replacing lock valve does not work, and no contamination is found in the old valve, Change the cylinders.

cbcb

Testing of full system by using a battery load tester:

1.1) Ground battery load tester on tractor chassis1.2) Hook up positive load tester cable on positive pole of single pole plug on front of trailer. 1.3) Run load test- This will test entire circuit on trailer including ground between tractor and trailer and circuit breaker on trailer.

2.1) Ground battery load tester on trailer chassis 2.2) Hook up positive cable on positive pole of single pole plug on tractor. 2.3) Run load test- This will test entire circuit on tractor including ground between tractor and trailer and circuit breaker on tractor.

A simple voltage test at the front of the trailer or at the tractorwill not show problems like this test

TRAILER CHARGE TEST ON ENTIRE CHARGE SYSTEM

Hydr. Close Valve B

Hydr. Open Valve A

Pressure Adjustment for Power Down 500 psi

Pressure for Platform power open 1500 psi

Master Switch

Lowering Valve C Relay

Operating liftgate up Lock Valve is activated and the motor Operating liftgate down Lock Valve opens, lowering valve C andOperating the power open Relay is used here. Relay directs pomotor for opening. Operating the power close Relay is used here. Relay directs poMotor for closing Why the relay is used? The relay is used to direct power to eitherthe motor solenoid to activate the motor without activating the “Lock

Lock Valve Pressure Gauge 3000 PSI

15A Circuit Breaker Protectpower line to switch

Pressure Adjustment for UpFunction and Platform Close

Single Power unit Hydraulic ILD

the motor activated wer to valve B and

wer to valve A and

the coil A or coil B and Valve”.

Dual Power Unit Hydraulic ILD

Hydr. Close Valve B

Master Switch

Lock Valve Pressure Gauge 3000 PSI

Pressure for Platform power open 1500 psi
Pressure Adjustmentfor Power Down 500 psi
Pressure Adjustment for Up Function and Platform Close Max 3000 PSI On dual power units both pumpsneed adjustment for up pressure.

Hydr. Open Valve A Lowering Valve C

Relay 15A Circuit Breaker protects line to switch

Operating liftgate up Lock Valve and the motors are activated Operating liftgate down Lock valve opens, lowering valve C and the motors are activated Operating the power open Relay is used here. Relay directs power to valve B and motor for opening Operating the power close Relay is used here. Relay directs power to valve A and motor for closing Why the relay is used? The relay is used so that we can direct power to either the coil A or coil B and the motors solenoids to activate the motors without activating the “Lock Valve”.

ILD Liftgate trouble shooting guide 1.1) Check voltage minimum 10 volts at motor at by pass. 1.2) Motor does not run. Check motor solenoid. If it is getting power but you Do not hear click, you should change the motor solenoid. 1.3) If the motor solenoid is getting power and you can hear it click, replace motor. 2.1) Liftgate makes squealing noise:

a. Noise happens in both raising and lowering. Use Caterpillar additive 1U-9891. Start with 2 ounces, engage up switch to by-pass and hold for 30 seconds then cycle liftgate 4-5 times or until noise stops. Add two ounces more at a time until noise stops. Maximum 8 ounces. If after 8 ounces the noise does not stop or diminish contact factory.

b. Noise happens only when it’s lowering.

Lower the pressure on the down function. If lowering the pressure does not work, you will need to change the pressure compensating valve located on the top of the passengers side cylinder.

2.2) Liftgate will not raise:

a. Motor runs but nothing is happening or platform raises slow. Check your batteries. Batteries are not charged or weak. Recharge or replace batteries. Use a booster if necessary to rule out battery problems.

b. Check power on lock valve and lowering valve with up button activated. c. If you are getting power on the lowering valve and lock valve, replace the diode on the green wire. Lowering valve should not get power when raising platform. d. If you are getting power only to the lock valve: The lock valve should

have at least 10V. (It is Important to have volt meter to perform proper test). If valve has power to it, put your finger on the valve block while activating the switch and feel if the valve is actually switching. If it feels like it is but the

liftgate operates slow, put a booster on your batteries. If the booster solves the problem, check you batteries again, they are probably not holding a charge. If booster does not help, replace valve and coil.

e. If you are not getting power: Follow the schematic through to the switch to find, either the faulty wire that may be broken or a faulty switch. Usually, if this is a switch problem, one of the two switches will work fine. If both switches do not turn the liftgate on, then you probably have a broken wire inside the pump & motor box.

f. Motor runs but platform goes down when the up button is pressed.

Hoses are reversed where they connect to the power unit box. 3.1) Platform does not lower down

a. Motor does not run. If it is not getting power, follow the schematic through wiring to check for power to the switch to find either the faulty wire that may be broken or a faulty switch. Usually if this is a switch problem one of the two switches will work fine. If both switches do not run the liftgate down, then you probably have a broken wire.

b. Motor runs but platform does not move or moves slow.

Check power on both lock valve and lowering valve when switch’s are activated. Test first with each switch activated individually.

c. No power at coil. Determine by following the schematic diagram Bad switch or broken wire? Make sure master switch is on and circuit breakers are not tripped.

Note: There are diodes in some wires that may be faulty. If you have a wire with a diode in it, it is most likely is a bad diode. Replace it.

d. Lock valve has power and lowering valve has power.

If in your test for lowering, the gate raises fine but just will not lower, it most likely is a bad lower valve and coil. Feel the valve when activating switch. You should feel a pulse on the valve and hear it click. If you can’t feel the valve activate or hear a clicking, change the valve and coil. Holding a screw driver on the end while coil is activated should create a magnet and pull the screwdriver in. If it does not coil is bad replace it.

Pressure compensating valve is loose or contaminated. Located in right side lift cylinder, retighten or clean out.

3.2) Platform does not open or close. a. Motor does not run. Check motor solenoid. If it is getting power but you do not hear click, you should change the motor solenoid.

b. Motor Runs but platform does not move. Check power on both coils of open and close valve.

c. No power at coil.

Determine by following the schematic diagram. Bad switch or broken wire? Make sure master switch is on and circuit breakers are not tripped.

Note: There are diodes in some wires that may be faulty. If you have a wire

with a diode in it check for power flow to rule out a bad diode first.

e. Coil has power. If in your test the platform closes fine but will not open (or the opposite) either the one coil is bad or the valve. If coil is getting power you can reverse the two coils and try the function again. If the one coil is bad the opposite will happen. If the opposite does not happen replace the coils and valve. If the opposite does happen replace only the bad coil.

Fittings with orifices plugged

Hydraulic hose plugged Hydraulic pressure set to low

3.3) If the platform does not close:

a. Motor is running Check for power at the open valve/coil. When the switch for open/close is activated, there should be power at the coil.

If you have power and nothing happens try activating both up button and open button to check for power at the lock valve. You should not be getting power to the lock valve if the open switch is activated and the up button is activated.

If you have power on the lock valve the relay is not kicking in. Follow the Schematic to make sure the relay is kicking in to prevent power going to the lock valve. Change relay if it is faulty.

If you are not getting power to the lock valve when you press the up button change the valve and coils. If you do not have power, follow the schematic wiring diagram to check for possible broken wire. If after changing the valve it still does not work contact factory.

b. Motor not running Check motor solenoid. If it is getting power but you do not hear it clicking, you should change the motor solenoid. If it does not have power, follow the

schematic to find the broken wire or diode and repair as necessary. 3.4) Platform does not close. If platform opens fine but just will not close check for power at coil that activates the valve for opening. If it does not have power, follow the schematic to find the broken wire. Check also that the relay is functioning properly. Follow the schematic.

4.1) Platform opens or closes to slow.

The hydraulic cylinder that power closes and opens the platform has 90 degree fittings with orifices. Platform should be lowered to the ground and the fittings removed for inspection. The hole in the orifice should be no larger than 1/64”. A welding tip cleaner can be used to clean the hole out if it is contaminated.

5.1) Platform will not lock properly on both sides.

Power the liftgate platform up to the top before locking the platform. Hold the button at the top for 5-10 seconds to relevel the platform. Sometimes if the platform goes out of sync it may need to be relevelled at the top before it goes into the locks properly.

6.1) Platform leaks down.

Run platform to the top and hold the button for 30 seconds to bleed the system through, before determining if there is any leakage.

a. Does only one side leak down?

Yes: Replace cylinder on that one side where it is leaking. Some leaking overnight is normal. Contact factory before changing cylinder. No: Check lock valve. Lock valve may have dirt or contamination causing it to leak down. Lower platform to the ground, remove the lock valve and coil. Clean the valve and reinstall. If it still leaks down replace the lock valve.

7.1) Checking the Oil level in the Tank Always check the oil with the platform in the raised position at floor level. The oil level should be about 1” below the top of the filler or just visible in the sight glass.

WIRING FOR DEUTSCH CONNECTOR

1. Insert the pins on the end of the wire through the appropriate labeled hole

on the back of the connector until the pin snaps in place. Carefully pull back on the wire to make sure it is locked in the connector.

PINW IRE

COLORA BLACKB W HITEC GREEND REDE ORANGEF BLUE

2. Insert all pins as shown to the wiring instructions above.

3. Tool to remove pins is available thru Parts Department.

O

ILD Wear Pad Replacement

Wear Pad, Lower Back Step 1 Store platform in drop in latches Step 2 On passenger side remove the 2 screws holding the Power Open & Close guard to Column.

Step 3 Unbolt the 4 bolts holding the wear pad as shown (Dock Bumper Plate not shown.)

Power open & close guard


Step 4 Grab on to bottom of steel wear pad bracket and pull downward to remove pad assembly. Note: Slider may need to be pried off of wear pad to slide downward

Step 5 Replace wear pad by removing the 4 screws from the wear pad assembly to remove UHMW wear pad.

Step 6 Attach new UHMW wear pad to bracket and reattach bracket to liftgate.


Wear Pad, Upper Front Step 1 Store platform in drop in latches Step 2 Remove the 2 screws holding the column cover in place and remove column cover.

Column Cover

Step 3 Remove the 2 – 3/8 bolts holding the top front pad assembly in place.

3/8” bolts


Step 4 Lift the wear pad assembly out top of column.

Wear Pad Assembly

Step 5 Replace wear pad by removing the 6 screws from the wear pad assembly.

6 wear pad screws

Step 6 Attach new UHMW wear pad to bracket and reattach bracket to liftgate.

Closing Hose Sleeve Replacement 69130 Parts List

Part # Description Qty 69046 HOSE, 40" LONG ‐ 125 WATER DISCHARGE 1 68398 HOSE, 3C1T, 120" OAL COUPLED W/ 4FJX BOTH ENDS 1 68399 HOSE, 3C1T, 128" OAL COUPLED W/ 4FJX ‐ 4MJ 1 16657 SWITCH, MOLDED, UP/DWN 16FT W/ CONNECTOR 1 68417 HOSE RETAINING BRACKET, 2" 2 16195 BOLT, 5/16‐18 x 1 1/2", GR5 2 69194 SWITCH ADAPTER BRACKET 1 10265 NUT, 5/16, NYLOCK 2 16659 SCREW, SELF TAPPING, 1/4‐20 x 1 1/4 2 68434 SCREW, #6‐32 x 3/4", SELF TAPPING 2

1. Remove existing hoses, E-chain, slider switch and hose guard.

2. Drill 3/8” hole between existing E-Chain attachment holes in column as shown.

3/8” hole drilled between existing E‐chain holes.

1. Drill 3/8” hole between existing E-Chain attachment holes in slider hose guard as shown.

3/8” hole drilled in slider hose guard Slider hose guard

Page 1 of 3

Closing Hose Sleeve Replacement 2. Slide hoses and switch wire through rubber hose sleeve.

3. Locate hole in rubber hose sleeve with new 3/8” hole in column.

4. Bolt hose bracket, hose sleeve and hoses to back of column with 5/16” bolt as shown.

Hose clamp

Bolt through hose clamp and sleeve to 3/8” hole drilled in column.

5. Wrap hose sleeve around and run hoses through POC bracket support.

Note: The shorter hose should be extending 8” past the end of sleeve and the longer hose 16 ½” past end of sleeve to attach to closing cylinder. The switch wire should extend approximately 31 ½” past end of the sleeve.

POC bracket support

6. Bolt hose bracket, hose sleeve and hoses to slider hose guard with 5/16” bolt as shown.

Bolt to hose bracket to slider hose guard Slider hose guard

Page 2 of 3

Closing Hose Sleeve Replacement 7. Locate hose guard and bolt hose guard to slider.

8. If replacing push button switch, attach the switch adapter plate to the slider using the #6 x ¾” screws provided.

SWITCH ADAPTER BRACKET

9. Install molded switch to adapter bracket with two ¼” x 1 ¼” self threading screws provided.

MOLDED SWITCH

Page 3 of 3

ILDPARTS MANUAL

INTERLIFT, INC. a member of MBB

Visit our website at www.interlift.net for up to date information and notifications

If you received this product with damaged or missing parts, contact Interlift at 562-924-8318

8/30/07

15939 Piuma Ave., Cerritos, CA 90703 Tel (562) 924-8218 Fax (562) 924-8318

ILD™ Parts Manual

www.Interlift.net Tel: 562 924-82182

Introduction

Each Interlift liftgate is manufactured to stringent quality standards for years of reliable service. Toensure maximum performance of your Interlift liftgate, always specify and use “OEM Parts” fromInterlift.

This manual is a complete parts listing for ILD liftgates from 3500 lb. to 6600 lb. capacity. We haveprovided charts and diagrams to make the selection of the correct part as easy as possible.

This manual does not provide procedures for the servicing and repair of an Interlift liftgate. Service andrepair should only be performed by an authorized Interlift distributor. For information on the nearestauthorized Interlift distributor contact:

INTERLIFT, INC. a member of MBB.

15939 Piuma AveCerritos, CA 90703Tel (562) 924-8218

Fax (562) 924-8318

www.Interliftlift.net

* The use of non-standard or makeshift parts can be extremely hazardous and result in seriousinjury or death.

ILD™ Parts Manual


Table of Contents

Introduction.................................................................................................................................2

Table of Contents .......................................................................................................................3

General Information....................................................................................................................4

Ordering Information...................................................................................................................5

Key Components ........................................................................................................................6

H-Frame – ILD (Lifts Built before 9/08/2005) ..............................................................................7

H-Frame – ILD............................................................................................................................8

Platform – ILD35 and ILD44 .......................................................................................................9

Platform – ILD55 and ILD66 .....................................................................................................10

Platform – Aluminum ................................................................................................................11

Platform – Roll Stop Option (Option 501) .................................................................................12

Electrical Components (Lifts Built before 9/08/2005)................................................................13

Electrical Components..............................................................................................................14

Slider Assembly (Lifts Built before 9/08/2005) ..........................................................................15

Slider Assembly........................................................................................................................16

Cylinders, Hoses & Fittings.......................................................................................................17

Wear Pad Assembly .................................................................................................................18

Hydraulic Power Unit Assembly – Single Motor........................................................................19

Hydraulic Power Unit Assembly – Dual Motor (Lifts Built before 3/30/2006) ............................20

Hydraulic Power Unit Assembly – Dual Motor ..........................................................................21

Decals.......................................................................................................................................22

Help and Service ......................................................................................................................23

ILD™ Parts Manual


General Information

MODEL NUMBER CODINGThe code and model numbers of a liftgate are references to its size, type and capacity. Using thesenumbers when ordering or specifying improves customer satisfaction and delivery.

Model Number: ILD4472

ILD 44 721 2 3

1. LIFTGATE TYPEILD = Direct Lift Style Liftgate

2. WEIGHT CAPACITY35 = 3500 lb. Capacity44 = 4400 lb. Capacity55 = 5500 lb. Capacity66 = 6600 lb. Capacity

3. DEPTH OF PLATFORM (not including ramp)

60 = 60” of platform loading area72 = 72” of platform loading area84 = 84” of platform loading area

ILD™ Parts Manual


Ordering Information

STEP 2 Identify the Item number from the appropriate part in the assembly diagram.

STEP 3 Locate the appropriate row listing the Item number in the table below the assemblydiagram.

ITEM # DESCRIPTION ILD35ILD44

ILD55ILD66

1 SLIDER, LH 680042 WEAR PAD, UPPER BACK 680093 WEAR PAD PLATE, UPPER FRONT 68014

STEP 4 Locate the column in the table that matches your model liftgate.


ILD55ILD66


STEP 6 Find the correct part number.


ILD55ILD66


STEP 7 Order the part

Model Number: ILD4472Part Name: Slider, LHQuantity Required: 1Part Number: 68004

STEP 1 Determine the assembly on which the desired part is located using either the Table ofContents (page 2) or the Key Components diagram (page 5)

ILD™ Parts Manual

www

Key Components

PlatformILD35ILD55AlumiRoll S

Wear Pads:Pages 18

Power Unit:Single - Page 19Dual – Page 20

Decals:

.Interlift.net Tel: 562 924-82186

Page 21

H-Frame:Page 7 & 8

Cylinder, Hoses & Fittings:Page 17

Electrical:Page 13 &14

Sliders:Page 15 & 16

:, ILD44 – Page 9, ILD66 – Page 10num Option – Page 11top Option – Page 12

ILD™ Parts Manual


H-Frame – ILD (Lifts Built before 9/08/2005)

ITEM # DESCRIPTION96"

WIDE102"

WIDEQTY

COMPLETE ASSEMBLY 68784 68840 1

1 COLUMN, LH 68701 1

2 COLUMN, RH 68702 1

3 HOUSING THRESHOLD 68737 68833 1

4 HOUSING COVER 68795 68340 1

5 TRACK CAP 68542 2

6 BRACKET, CYLINDER SUPPORT 68003 2

7 LOCKING TAB, CYLINDER PIN 68018 2

8 PIN, CYLINDER 68017 2

9 POC COVER, FRAME 68762 1

10 BUMPER ASSEMBLY, LH 68387 1

11 BUMPER ASSEMBLY, RH 68388 1

12 BUMPER PAD 68588 2

13 TRAVEL LATCH, LH 68788 1

14 TRAVEL LATCH, RH 68785 1

15 WEAR PAD, LOWER BACK 68007 2

16 SPACER PAD, LOWER FRONT 68026 2

17 LIGHT BRACKET, OVAL LED 68164 2

18 GROMMET, OVAL LIGHT 16137 4

19 LED LIGHT, OVAL, RED 16416 4

20 SWITCH WIRE COVER 68892 1

21 SWITCH GUARD 68893 1

22 BUMPER SLIDE CHANNEL 68384 2

21

22

ILD™ Parts Manual


H-Frame – ILD

ITEM # DESCRIPTION96"

WIDE102"

WIDEQTY

COMPLETE ASSEMBLY 68784 68840 1

1 COLUMN WELD, LH 68546 1

2 COLUMN WELD, RH 69007 1

3 BUMPER WELD, LH 68387 1

4 BUMPER WELD, RH 68388 1

5 TRACK CAP 68542 2

6 WASHER, 3/8” LOCKING 10092 8

7 BOLT, 3/8” X 1 ½” 20209 4

8 BOLT, 3/8” X 3 ½” 30287 2

9 CYLINDER PLATE SPACER 68971 1

10 CYLINDER SUPPORT BRACKET 68003 2

11 LOCKING TAB 68018 2

12 CYLINDER PIN, UPPER 68017 2

13 BOLT, 3/8” X 1 ¼” 10085 6

14 TRAVEL LATCH ASSEMBLY, RH 68787 1

15 TRAVEL LATCH, RH 68785 1

1617

TRAVEL LATCH CAM 68786 1

1718

SCREW, 3/8” X 1 ¼”, FH 40096 1

18 LIGHT BRACKET, OVAL, LED 68164 2


20 LED LIGHT, OVAL, RED 16416 4

21 TRAVEL LATCH, LH 68788 1

22 BUMPER PAD 68588 2

23 HOUSING COVER 68795 68340 1

24 SCREW, ¼” X 5/8”, TAPPING 10255 3


26 BOLT, 3/8” X 5/8” 10520 2

27 SWITCH GUARD 68893 1

28 BUMPER SLIDE CHANNEL 68384 2

24

27

28

ILD™ Parts Manual


Platform – ILD35 and ILD44

Platforms are available in many different sizes,material types, and special options. The chart belowis given for general reference only.

When ordering replacement platform sections, pleaseprovide the following information:Platform Size Depth, Width, ThicknessRamp Type Fixed, Flip, Roll Stops

ILD35 and ILD45ITEM # DESCRIPTION

80x60+12 80x72+16 80x72+12 80x84+16 86x60+12 86x72+16 86x72+12 86x84+16QTY

PLATFORM ASSEMBLY 68441 68442 68443 68444 68445 68446 68447 68448 1

1 PLATFORM WELD, MAIN 68855 68715 68857 68798 1

2 PLATFORM WELD, RAMP 68856 68877 68818 68716 68858 68878 68806 68799 1

3 SIDE ARM WELD, RH 68887 68792 68887 68792 1

4 SIDE ARM WELD, LH 68888 68793 68888 68793 1

5 NUT, ½” 30046 8

6 U-BOLT 30045 4

7 SIDE CHAIN 30218 – 67” 30218 – 80” 30218 – 67” 30218 – 80” 2

8 PIN, SLIDER HINGE 68739 2

9 GREASE FITTING 68473 4

10 BUSHING, 1 ½” ID x 1 ½” 68119 2

11 PLATFORM STOP 68474 1

12 CHAIN HOLDER 68364 2

13 DOCK LOCK 68794 2

14 SCREW, 3/8” X 1, LOCKING 68961 2

15 PIN ASSY, FOLDING HINGE 68646 2

16 TRAVEL EAR, LH 68709 1

17 TRAVEL EAR, RH 68708 1

18 FLIP RAMP - 68435 - 68435 - 68438 - 68438 0/1

19 LATCH ASSY, FLIP RAMP - 68427 - 68427 - 68427 - 68427 0/1

20 HINGE, FLIP RAMP - 40094 - 40094 - 40094 - 40094 0/2

21 BUMPER, FLIP RAMP - 16213 - 16213 - 16213 - 16213 0/1

22 CHAIN, FLIP RAMP - 30302 - 30302 - 30302 - 30302 1

23 BOLT, 3/8 X 3 30284 2

24 BUSHING, 1” ID x ¾” 25445 1

10 11

See page 17 forclosing cylinderpin and retainer.

24

ILD™ Parts Manual


Platform – ILD55 and ILD66



ILD55 and ILD66ITEM # DESCRIPTION

80x60+12 80x72+16 80x72+12 80x84+16 86x60+12 86x72+16 86x72+12 86x84+16QTY

PLATFORM ASSEMBLY 68461 68462 68463 68464 68465 68466 68467 68468 1

1 PLATFORM WELD, MAIN 68859 68830 68861 68831 1


3 SIDE ARM WELD, RH 68887 68792 68887 68792 1

4 SIDE ARM WELD, LH 68888 68793 68888 68793 1

5 NUT, ½” 30046 8

6 U-BOLT 30045 4

7 SIDE CHAIN 68305 – 67” 68305 – 80” 68305 – 67” 68305 – 80” 2


9 GREASE FITTING 68473 4

10 BUSHING, 1 ½” ID x 1 ½” 68119 2

11 PLATFORM STOP 68474 1

12 CHAIN HOLDER 68364 2

13 DOCK LOCK 68794 2

14 SCREW, 3/8” X 1, LOCKING 68961 2

15 PIN ASSY, FOLDING HINGE 68646 2

16 TRAVEL EAR, LH 68709 1

17 TRAVEL EAR, RH 68708 1

18 FLIP RAMP - 68435 - 68435 - 68438 - 68438 0/1

19 LATCH ASSY, FLIP RAMP - 68427 - 68427 - 68427 - 68427 0/1

20 HINGE, FLIP RAMP - 40094 - 40094 - 40094 - 40094 0/2

21 BUMPER, FLIP RAMP - 16213 - 16213 - 16213 - 16213 0/1

22 CHAIN, FLIP RAMP - 30302 - 30302 - 30302 - 30302 0/1

23 BOLT, 3/8 X 3 30284 2

24 BUSHING, 1” ID x ¾” 25445 1

10 11

See page 17 forclosing cylinderpin and retainer.

24

ILD™ Parts Manual

www.Interlift.net

Platform – Aluminum

Platforms are available in many different sizes,material types, and special options. The chartbelow is given for general reference only.

When ordering replacement platform sections, please provide the following information:Platform Size Depth, Width, ThicknessRamp Type Fixed, Flip, Roll Stops

ITEM # DESCRIPTIO

PLATFORM A

1 PLATFORM A

2 PLATFORM A

3 SIDEPLATE W

4 SIDEPLATE W

5 SIDEPLATE W

6 SIDEPLATE W

7 NUT, ½”

8 U-BOLT

9 SIDECHAIN

10 PIN, SLIDER

11 GREASE FITT

12 BOLT, 3/8, TA

13 BUSHING, 1 ½

14 PLATFORM S

15 CHAIN HOLD

16 SCREW, 3/8 X

17 PIN ASSY, FO

18 LEVELING SH

19 SCREW, 3/8 X

20 SIDEARM WE

21 SIDEARM WE

22 LATCH ASSY

23 CHAIN, FLIP R

24 FLIP RAMP M

25 FLIP RAMP

26 BUMPER, FLI

27 BOLT, 3/8 X 1

28 BOLT, 3/8 X 3

29 BUSHING, 1”

13 14

See page 17 forclosing cylinder

Tel11

ILD Aluminum PlatformN

80x60+12 80x72+16 80x72+12 80x84+16 86x60+12 86x72+16

SSEMBLY 69061 69062 69063 69058 68691 69004

SSEMBLY, MAIN 69064 69059 68692

SSEMBLY, RAMP 69065 69069 69071 69060 68693 69003

ELD, MAIN, LH 68695 68346 68695

ELD, MIAN, RH 68694 68345 68694

ELD, RAMP, LH 68698 68348 68698

ELD, RAMP, RH 68697 68347 68697

30046

30045

ILD35 & ILD44 = 30218, ILD55 & ILD66 = 68305

HINGE 68739

ING 68473

PTITE 68937

” ID x 1 ½” 68119

TOP 68474

ER 68364

1, LOCKING 68961

LDING HINGE 68646

IM 68934

2 68954

LD, LH 6888868793LD, RH 6888768792, FLIP RAMP, AL - 69002 - 69002 - 69002

AMP - 30302 - 30302 - 30302

OUNT - 69066 - 69066 - 68366

- 68435 - 68435 - 68438

P RAMP - 16213 - 16213 - 16213

½ - 20209 - 20209 - 20209

30284

ID x ¾” 25445

pin and retainer.

29

A

B

C

D

E

F

Aluminum ExtrusionChart

Part 96” wideLiftgate

102 wideLiftgate

A 68915 68905

B 68913 68903

C 68916 68906

D 68914 68919

E 68912 68902

F 68917 68907

G 68911 68901

G –w/RS

68918 68908

: 562 924-8218

86x72+12 86x84+16QTY

68950 68949 1

68349 1

68367 68368 1

68346 1

68345 1

68348 1

68347 1

8

4

13FT

2

4

28

2

1

2

2

2

2

2

1

1

- 69002 1

- 30302 1

- 68366 1

- 68438 1

- 16213 1

- 20209 1

2

1

H 68910 68900

ILD™ Parts Manual


Platform – Roll Stop Option (Option 501)



80x60+12 80x72+12 86x60+12 86x72+12


ILD55ILD66

ILD35ILD44

ILD55ILD66

ILD35ILD44

ILD55ILD66

ILD35ILD44

ILD55ILD66

QTY


2 ROLL STOP EXT, BOTTOM 68920 2

3 ROLL STOP EXT, TOP 68909 2

4 ROLL STOP RETAINER, SLIDE 68396 2

STEEL 5 ROLL STOP RETAINER 68395 2

6 ROLL STOP SPRING 68440 4

78

PLATFORM ASSEMBLY, RAMP 69068 69071 69037 69015 1

8 ROLL STOP EXT, TOP, LH 69011 1

9 ROLL STOP EXT, TOP, RH 69012 1

10 PIN, ROLL STOP 69014 2

ALUM

11 SHOULDER SCREW, RS 69013 2

ALUMINUM PLATFORM

STEEL PLATFORM

D

G

H

E

Aluminum ExtrusionChart

Part 96” wideLiftgate

102 wideLiftgate

D 68914 68919

E 68912 68902

F 68917 68907

G 68911 68901

G –w/RS

68918 68908

H 68910 68900

ILD™ Parts Manual


Electrical Components (Lifts Built before 9/08/2005)

ITEM # DESCRIPTIONILD35ILD44

ILD55ILD66

QTY

1 POWER UNIT 68030 68839 1

2 POWER UNIT BOX 68676 1

3 SWITCH, SLIDER MOUNT 68337 1

4 SWITCH, MAIN 68891 1

5 BATTERY CABLE 68457 1

6 CIRCUIT BREAKER, 15 AMP 11062 1

7 HARNESS, TWO LIGHT 68231 2

8 BRACKET, TWO LIGHT, OVAL 68164 2


10 LIGHT, STOP, LED 16416 4

11 RELAY 20870 1

12 MASTER DISCONNECT 20450 1

13 WIRE HARNESS 68335 1

- DIODE IN HARNESS (NOT SHOWN) 16662 4

14 EXTENSION, 3 WIRE, 10FT 68942 1




BOX COVER – 28” WIDE 68678 116

BOX COVER – 24” WIDE 69075 1

17 WIRE ASSY, SLIDER SWITCH 68689 1


Slider SwitchReplacement Wire

17

Check coverwidth before

ordering.

18

ILD™ Parts Manual


Electrical Components

ITEM # DESCRIPTIONILD35ILD44

ILD55ILD66

QTY

1 POWER UNIT 68030 69088 1

2 POWER UNIT BOX W MOUNT 69034 1

3 BOX COVER - 39” WIDE 69045 1

MAIN SWITCH, MOLDED, 10 FT 688914

MAIN SWITCH, MOLDED, 4.5 FT 691361

5 SWITCH, SLIDER 16 FT 68337 1

6 HARNESS, TWO LIGHT 16093 2

7 BRACKET, TWO LIGHT, OVAL 68164 2


9 LIGHT, STOP, LED 16449 4

10 BATTERY CABLE, 40 FT 68457 1

11 CIRCUIT BREAKER, 15 AMP 11062 1

12 DISCONNECT 20450 1

13 WIRING HARNESS 69078 1

- DIODE IN HARNESS (NOT SHOWN) 16662 4

14 CIRCUIT BREAKER, 150 AMP 20831 1/2

EXTENSION, 6 WIRE, 10 FT 68941




1





1

17 RELAY 20870 1

18 BULKHEAD, 3/8” 68059 2

19 BULKHEAD, ¼” 20532 2

20 FITTING, 3/8 JIC, SWIVEL 68073 1

21 FITTING, ¼ JIC, SWIVEL 68072 1

22 STRAIN RELIEF, 7/8 16049 3

23 WIRE ASSY, SLIDER SWITCH 68689 1


25 HOSE & WIRE GUIDE 96” LONG 68380 1

MOLDED SINGLE TOGGLE, 16 FT 1665726

MOLDED SINGLE TOGGLE, 9.5 FT 691371

27 CIRCUIT BREAKER,150A, AUTO RESET 20806 1

Slider SwitchReplacement Wire

25

24

26 27

When orderingextension hoses orswitches (items 4, 15,16 & 26) choose thepart number for thelength that matchesyour existing part.

ILD™ Parts Manual


Slider Assembly (Lifts Built before 9/08/2005)

PLATFORM DEPTHITEM # DESCRIPTION

60+12 72+16 72+12 84+16QTY

SLIDER ASSEMBLY, LH 6876068760

1

SLIDER ASSEMBLY, RH 6877068770

1

1 SLIDER, LH 68704 1

2 SLIDER, RH 68705 1

3 WEAR PAD PLATE, UPPER BACK 68009 2

4 WEAR PAD PLATE, UPPER FRONT 68014 2

5 WEAR PAD, UPPER BACK 68011 2

6 WEAR PAD, UPPER FRONT 68024 2

7 WEAR PAD, CYLINDER 68048 4

8 SWITCH, SLIDER MOUNT 68337 1

9 HOSE GUARD 68533 1

10 PIN, POC, UPPER 68529 1

11 LOCKING TAB, CYLINDER PIN 68018 2

12 PIN, CYLINDER, LOWER 68033 2

13 HINGE TUBE 68623 2

14 HINGE PIN 68739 2

15 PLATFORM CLOSING STOP 68474 2

15

ILD™ Parts Manual


Slider Assembly

ITEM # DESCRIPTION Part # QTY

1 SLIDER WELD, LH 68543 1

2 SLIDER WELD, RH 68544 1

3 HOSE GUARD 69000 1


5 PIN, CYLINDER, LOWER 68033 2

6 LOCKING TAB 68018 3

7 PIN, 1 x 2 3/8, SLOTTED 69091 1

8 PLATFORM CLOSING STOP 68474 1

9 SWITCH, 2 BUTTON 68337 1

MOLDED SINGLE TOGGLE, 16 FT 1655710

MOLDED SINGLE TOGGLE, 9.5 FT 691371

10

Verify the type of switch you have before ordering.

Item 9 – Push button switchItem 10 –Toggle switch

ILD™ Parts Manual

www.Interlift.net17

Cylinders, Hoses & Fittings

ITEM #

1

2

3

4

5

6

7

8

9

10

11

12

13

14

15

16

17

18

19

20

21

22

23

24

25

26

27

28

29

30

31

32

33

34

35

E-chain Replacement KitHoses and switch wire arepre-assembled in e-chain.

34

When orderingextension hoses orswitches (items 14, 15,27 & 28) choose thepart number for thelength that matchesyour existing part.

Sleeve Replacement Kit

Hoses and switch wire arepre-assembled in sleeve.

Tel: 562 924-8218

DESCRIPTIONILD35ILD44

ILD55ILD66

QTY

LIFT CYLINDER, RH 68022 68025 1

LIFT CYLINDER, LH 68025 68027 1

SLEEVE, PROTECTION 69046 1

HOSE GUIDE, E-CHAIN 68475 1

VALVE, PRESSURE COMP 6849068490

1

FITTING, 90, 9/16 ORB X 3/8 JICM 68363 2

FITTING, 9/16 ORB X 3/8 JICM 68057 2

LOCKING TAB 68018 6

WASHER, 3/8” LOCKING 10092 4

BOLT, 3/8 X ¾ 30027 6

PIN, CYLINDER, UPPER 68017 2

HOSE, HP, 3/8 X 88.5” 68391 2

HOSE, HP, 3/8 X 86.5” 68379 1

HOSE, HP, 3/16 X 120” 68398

HOSE, HP, 3/16 X 90” 691351

HOSE, HP, 3/16 X 128” 68399

HOSE, HP, 3/16 X 98” 691341

HOSE RETAINING BRACKET 68763 1

BOLT, 5/16 X 1 10075 1

RETAINING RING 68962 2

PIN, OPEN/CLOSE CYLINDER 68529 2

CYLINDER, OPEN/CLOSE 68738 1

FITTING, 90, 9/16 X ¼ JICM, TAP 68362 2

FLOW RESTRICTOR ORIFICE 68312 2

HOSE, HP, 3/8 X 160”, FEMALE 68067

HOSE, HP, 3/8 X 122”, FEMALE 691321

HOSE, HP, 3/8 X 160”, MALE 68068

HOSE, HP, 3/8 X 118”, MALE 691331

HOSE, HP, 3/8 X 108” 68390 1

PIN, CYLINDER, LOWER 68033 2

HOSE, HP, ¼ X 10 FT 68944

HOSE, HP, ¼ X 23 FT 68196

HOSE, HP, ¼ X 13 FT 69138

HOSE, HP, ¼ X 26 FT 69142

2

HOSE, HP, 3/8 X 10 FT 68943

HOSE, HP, 3/8 X 23 FT 68195

HOSE, HP, 3/8 X 13 FT 69139

HOSE, HP, 3/8 X 26 FT 69143

2

E-CHAIN ASSEMBLY 68978 1

CLEVIS ONLY, SCREW ON, 68852 1

PIN, 1 x 2 3/8, SLOTTED 69091 2

HOSE RETAINING BRACKET, 2" 68417 2

BOLT, 5/16 x 1 1/2 16195 2

HOSE & WIRE GUIDE 96” LONG 68380 1

SLEEVE, HOSE, SWITCH&CLAMP KIT

69130 1

35

ILD™ Parts Manual


Wear Pad Assembly

ITEM # DESCRIPTION Part # QTY

1 BOLT, 3/8 X 1 ¼ 10085 8

2 WASHER, 3/8 LOCKING 10092 8

3 WEAR PAD PLATE, UPPER BACK 68009 2

4 WEAR PAD, UPPER BACK 68011 2

5 SCREW, 5/16 FLAT HEAD LOCKING 68850 20

6 WEAR PAD, CYLINDER 68048 4

7 RIVET, ¼ 40198 8

8 WEAR PAD PLATE, UPPER FRONT 68014 2

9 WEAR PAD, UPPER FRONT 68024 2

10 WEAR PAD PLATE, LOWER BACK 68006 2

11 WEAR PAD, LOWER BACK 68007 2

12 BOLT, 3/8 X ¾ 30027 12

13 WEAR PAD, LOWER FRONT 68026 2

SLIDER, UPPER, BACK SLIDER, CYLINDER PAD

SLIDER, UPPER, FRONT

COLUMN, LOWER, BACK

COLUMN, LOWER, FRONT

ILD™ Parts Manual


Hydraulic Power Unit Assembly – Single Motor

ITEM # DESCRIPTION PART # QTY ITEM # DESCRIPTION PART # QTY

POWER UNIT ASSEMBLY 68030 1 12 FITTING, ¼ NPTM X 3/8 NPTM 20672 1

1 MOTOR 25163 1 13 FITTING, ¼ NPTM X 9/16 O’RING 68049 1

2 RESERVOIR 68234 1 14 FITTING, 3/8 NPTM X 3/8 JICM 68055 1

3 SOLENOID, 12VDC 16637 1 15 FITTING, ¼ JICM X 9/16 O’RING 68056 2

4 VALVE, 4W2P, CARTRIDGE 68224 1 16 FITTING, 3/8 JICM X 9/16 O’RING 68057 1

5 VALVE, 4W3P, CARTRIDGE 68225 1 17 FITTING, ¼ NPTF TEE 68058 1

6 VALVE, RELIEF, MAIN 68226 1 18 PRESSURE GAUGE 68061 1

7 VALVE, RELIEF, POWER DOWN 68227 1 19 VALVE, BI DIRECTION LOCK 68149 1

8 VALVE, RELIEF, POC 68230 1 20 HOSE, ¼” JICF 68392 2

9 VALVE, P.O. CHECK 69076 1 21 HOSE, 3/8” JICF 68393 2

10 CABLE, SOLENOID 10022 1 22 DIN CONNECTOR ASBLY 20879 1

11 FILLER CAP 20979 1

22

ILD™ Parts Manual


Hydraulic Power Unit Assembly – Dual Motor (Lifts Built before 3/30/2006)


POWER UNIT ASSEMBLY 68839 1 13 FILLER CAP 20979 1

1 MOTOR 25163 2 14 FITTING, ¼ NPTM X 3/8 NPTM 20672 1

2 RESEVOIR 68629 1 15 FITTING, ¼ NPTM X 9/16 O’RING 68049 1

3 SOLENOID, 12VDC 16637 2 16 FITTING, 3/8 NPTM X 3/8 JICM 68055 1


5 VALVE, 4W3P, CARTRIDGE 68225 1 18 PRESSURE GAUGE 68061 1

6 VALVE, RELIEF, MAIN 68226 1 19 VALVE, BI DIRECTION LOCK 68149 1

7 VALVE, RELIEF, POWER DOWN 68227 1 20 HOSE, ¼” JICF 68392 2

8 VALVE, RELIEF, POC 69077 1 21 HOSE, 3/8” JICF 68393 2

9 VALVE, CHECK 25477 2 22 HOSE, CONNECTING, 3/8” 68768 1

10 FITTING, 3/8 JICM X 9/16 O’RING 68057 1 23 FITTING, 3/8, 90 deg. swivel 68769 2

11 FITTING, ¼ JICM X 9/16 O’RING 68056 2 24 DIN CONNECTOR ASBLY 20879 1

12 CABLE, SOLENOID 10022 2 25 VALVE, P.O. CHECK 69076 1

23

22

24

25

ILD™ Parts Manual


Hydraulic Power Unit Assembly – Dual Motor


POWER UNIT ASSEMBLY 69088 1 12 HOSE, ¼” JICF 68392 2

1 MOTOR 25163 2 13 HOSE, 3/8” JICF 68393 2

2 RESEVOIR 69107 1 14 FITTING, ¼ JICM X 9/16 O’RING 68056 2

3 SOLENOID, 12VDC 16637 2 15 FITTING, 3/8 JICM X 9/16 O’RING 68057 1

4 VALVE, 4W2P, CARTRIDGE 69098 1 16 FITTING, ¼ NPTM X 9/16 O’RING 68049 1


6 VALVE, RELIEF, MAIN 68226 2 18 FITTING, ¼ NPTM X 3/8 NPTM 20672 1

7 VALVE, RELIEF, POWER DOWN 68227 1 19 PRESSURE GAUGE 68061 1

8 VALVE, RELIEF, POC 69077 1 20 FITTING, 3/8 NPTM X 3/8 JICM 68055 1

9 VALVE, CHECK 69108 1 21 CABLE, SOLENOID 10022 2

10 VALVE, P.O. CHECK 69109 1 22 FILLER CAP 20979 1

11 VALVE, BI DIRECTION LOCK 68149 1

ILD™ Parts Manual


Decals

Properly placed warning decals are an essential part of your safety program. Check that all safetydecals are in place and are legible. Any missing decals MUST be replaced immediately.Replacement decals may be obtained FREE of charge from your distributor or by phoning, writing, orfaxing us.

Following are the proper decals that you should have and their proper locations:

ITEM # DESCRIPTION ILD35 ILD44 ILD55 ILD66 QTY

1 OPERATING INSTRUCTIONS 68845 1

2 WARNING, KEEP CLEAR 20425 1

3 WARNING, MAX. CAPACITY 68846 68217 68847 20875 2

4 URGENT WARNING 16181 1

5 DANGER, LIFTGATE CAN CRUSH 16184 2

6 SAFETY, OPEN AND CLOSE 68683 1

7 OPEN AND CLOSE DECAL 68945 1

ILD™ Parts Manual


Help and Service

With careful maintenance and operation your Interlift liftgate should give you years of trouble freeuse. If a problem does develop, contact your liftgate distributor. They are best equipped to serviceyour liftgate.

If you have suspected warranty problems, contact the distributor from whom you purchased theliftgate. They will normally process your claim from start to finish.

Your distributor will repair your liftgate and get you on the road as quickly as possible. They mayinvoice you for this service. If the problem is found to be warrantable by Interlift Inc., Interlift Inc. willissue your Distributor a credit, which should then be credited back to you.

ILD Series™ Maintenance & Service Manual

ILD SeriesRail Style Liftgate

™

Read Before Operating

MAINTENANCE & SERVICE MANUALFor Models: ILD35 • ILD44 • ILD55 • ILD66

Interlift, Inc.a Subsidary of MBB Liftsystems AG

15939 Pluma AvenueCerritos, CA 90703 USA

(562) 924-8218888-774-1335

Fax (562) 924-8318

www.interlift.net

3/2005

Part #:68485

1


Description Page

Theory of Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2

Preventative Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5

Trouble Shooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15

Key Electrical Components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21

Key Hydraulic Components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .25

TABLE OF CONTENTS

2


Theory of Operation

The rail-type direct lift vertical liftgate is designed to lift cargo verticallyfrom the vehicle bed to the ground and vice versa. A hydraulic powerunit provides power to two vertical cylinders that raise and lower theplatform. Activation of a control switch supplies current from a 12-voltbattery to the hydraulic power unit. The hydraulic power unit in turnsupplies hydraulic fluid to the hydraulic cylinders, causing them toretract. The resultant upward pull on the sliders raises the platform.

The platform is lowered by hydraulic power. Activation of the controlswitch directs hydraulic fluid to extend the cylinder. The resultantdownward force on the sliders lowers the platform.

The platform opens and closes hydraulically. The platform is closed bydirecting hydraulic oil from the hydraulic power unit to the HydraulicPower Open and Close Cylinder, extending the cylinder. The platformopens hydraulically by directing hydraulic oil to the Hydraulic PowerOpen and Close Cylinder, retracting the Hydraulic Power Open andClose Cylinder.

3


Design Detail

ILD Series Liftgate

Hinge PinPlatform

Slider RightHand

SliderLeft Hand

Inner Section,Platform

Outer Section,Platform

Hinge Tube, Slider

Hydraulic Open & Closecylinder (“POC”)

Slider WearPads

Lift Cylinder

Column Right Hand

ColumnLeft Hand

Ramp

4


Design Detail

Lift Cylinder

12 Volt Power Supply

Control SwitchAssembly

Flow Control Valve

Power Unit

Power System

5


We strongly recommend that operators use our preventive maintenanceschedule as a means of keeping their liftgate running at its best. Werecommend that the Daily Overall Inspection should be performed bythe operator each day. As well, we recommend that the operatorperform the Periodic Lubrication according to the chart on page 11.The Routine Maintenance Inspection should be performed semi-annually by an Authorized Service Center. Performing Daily OverallInspection and Periodic Lubrication and having semi-annual RoutineMaintenance Inspections performed, should ensure years of safe,trouble free operations.

The operator’s first visit to an Authorized Service Center should occuronce the liftgate has been in operation for 30 days. The importance ofthis initial inspection is to make sure that everything is working properlyduring this break in period. Once this is complete, we recommend thatthe operator return semi-annually to his or her Authorized ServiceCenter for performance of the Routine Maintenance Inspection.

1. PREVENTIVE MAINTENANCE

1.1 Essential Maintenance

6


1.2 Daily Overall Inspection

STEP 2 Inspect liftgate for missing or loosened fasteners, broken welds, signs of overload, hydraulic leaks and that pins are in place and secured.

Any defects need repair immediately. Contact your Authorized Service Center.

STEP 1 Run liftgate through its entire cycle daily. Check for any unusual noises coming from the liftgate or related items such as the power unit.

STEP 3 Check that all warning decals are in place and legible.Any missing or damaged decals need replacement immediately.

7


You may obtain free replacement decals (See page 17 for detaileddescription of decals) by phoning us at 888-774-5844 in USA.Have your liftgate model # and serial # ready.

NOTE: Please fill out the chart provided, as a reminder that thesesteps have been completed daily. You will find a sample of this chart onthe page that follows. Contact your employer to receive a copy to keepin your glove compartment.


1. Operating Instructions2. Warning Keep Clear3. Warning Maximum Load Capacity

4. Urgent Warning5. Warning Liftgate Can Crush

8


SAMPLE OF DAILY CHECK CHART

Do not operate the liftgate if everything does notcheck out properly during its daily inspection.Liftgate may malfunction causing severe personalinjury or death. Liftgate should be inspectedIMMEDIATELY by an Authorized Service Center.

Liftgate Signs of Hydraulic Support SafetyCycle Fastener Weld Overload Leak Chains Decal

Date Check Check Check Check Check Check Check

6/9/01 MS MS MS MS


9




Company Name Driver's name

Fleet Supervisor Vehicle #

Date liftgate was put into service Vehicle Make & Model

Authorized Service Center Liftgate Model & Serial #

Friendly Reminder - your liftgate is due for its initial 30 day inspection in 15 days


This model chart is provided for your convenience, and may be photocopied.

10





Your liftgate MUST have its initial 30 day inspection completed at this time.

11


1.3 Periodic Lubrication

Lubrication with lightweight machine oil should be performed at leastmonthly. Heavier usage will require more frequent lubrication consult the chart below. If you are in any doubt as to duty or number of cycles,lubricate more frequently.

Cycles per Day Light Duty1 Medium Duty2 Heavy Duty3

Under 20 1 month 1 month 1 month

20-40 1 month 1 month 2 weeks

40-60 1 month 2 weeks Weekly

Over 60 Consult factory Consult factory Consult factory

1 Lowering rated load and lifting empty platform2 Lowering rated load and lifting 1/2 rated load3 Lowering rated load and lifting

12


1.3 Periodic Lubrication

Lubricate only the areas shown on the diagram below. Lubricationof any other areas will shorten the life of the area lubricated.

LUBRICATION DIAGRAM

Oil - Wear Pads Upper Back and Upper Front

both sides

Oil - Wear Pads Lower Backboth sides

Grease - Platform Folding Pin both sides

Grease - PlatformHinge PIns both

sides

13


1.3 Semi-Annual Routine Maintenance Inspection

Inspection Procedure Minutes

Inspect Liftgate tracks: 10

a. For any physical damage, twisted, bend, spreading,broken welds, top and bottom.

b. Inspect for loose or missing bolts.

Inspect Liftgate platform: 15

a. For any signs of overload damage, cracked or broken welds.

b. Inspect the folding hinges on the platform and ramp for wearing.

c. Inspect platform side chains, adjusting bolts, chain clevis,side arm assembly, side attachment assembly for bent or missing parts.

d. Inspect platform for adjustment- should be level with the vehicle floor in the fully raised position and is parallel with the vehicle floor in the up and open position.

e. Inspect platform hinge tube bushing (removal of platform required). 60

Inspect Liftgate slider assembly 10

a. For cracked or broken welds on hinge tube.

b. That pins are secure by making sure the pin retainers are in place and the retainer bolts are not loose or missing.

c. Inspect wear pads for wear and bracket for missing or broken bolts.

d. Inspect slider for straightness or physical damage.

Inspect Hydraulic and Electrical Components

a. For hydraulic leak on cylinder and hoses. 15

b. Hoses for fraying or cracking

c. Remove power unit enclosure cover and inspect that electrical connections are secure – spray connection with dielectric grease.

Based on an average usage of 20 to 40 cycles per day.

14


Inspection Procedure Minutes

Inspect Hydraulic and Electrical Components (cont.)

d. Fluid level in tank is1/2" from the top with platform all the way up.

e. Inspect for any visible oil leaks in the power unit enclosure.

f. Power unit to make sure mounting is secure.

g. Master disconnects switch works properly and battery connection are secure. Lubricate terminal exposed to the elements using dielectric grease.

h. Circuit breaker for visual damage and battery connection are secure. Lubricate exposed terminals with dielectric grease.

i. Inspect entire length of battery cable and exposed switch wiresfor chaffing.

j. Inspect switch box for loose connections and spray with die-electric grease.

Inspect dock protectors

a. Check for bent or broken steel bumper plate on broken/missing bolt. 5

b. Inspect for loose or missing bolts on rubber bumpers.

c. Inspect for missing or damage rubber bumpers.

Final Inspection

a. Run gate through two entire cycles with platform open to make sure there is no unusual noise. 5

b. Run gate through one cycle of the power open and close operation.

c. Run gate up to stored position, make sure platform lock works properly.

Total 60

1.3 Semi-Annual Routine Maintenance Inspection

15


2. TROUBLE SHOOTING

Liftgate will not raise orraises slowly, unloaded

• Motor not running

• Little or no hydraulic oil in the reservoir

• No oil supply to cylinder

• Defective lift cylinder

• Hydraulic flow valve on cylinders malfunctioning

• Mechanical damage or obstruction

• Hydraulic oil thickened due to low temperature

• Check Master Disconnect is "ON"

• Check that Circuit Breaker has not been tripped

• Check for shorts, ground faults or open circuits,e.g., power lines connected to the ground or a broken cable or connection

• In below freezing temperatures, check for frozen water accumulationin the motor housing

• Check motor solenoid. Replace if non-functional

• Check control switch. Replace if non-functional

• Fill with correct hydraulic fluid

• Check for any broken or blocked hoses, valves or filters

• Check function. Replace ifnon-functional


• Check for and remedy any damage or obstruction in sliders, track or path of travel of platform

• Change to lower viscosity hydraulic oil

Problem Possible Cause Remedy

16



Liftgate will not raise orraises slowly, loaded

• Reduced hydraulic oil delivery to the cylinder

• Ground Fault

• Liftgate overloaded

• Pump worn

• Pressure relief valve out of adjustment

• Insufficient oilin reservoir

• Air in hydraulic system


• Check voltage supply to motor. Minimum should be 10.5 volts under load. If voltage is too low, increase the power supply

• Check for poor electrical connections

• Check the ground from the chassis to the battery (minimum #4 battery cable)

• Check the ground from the chassis to the motor (minimum #4 battery cable)

• Decrease load

• Have pump serviced or replace

• Adjust

• Fill with hydraulic oil

• Raise and lower the liftgate several times andthen fill the reservoir withhydraulic oil


Liftgate will not raise to full height

2. TROUBLE SHOOTING

17


Liftgate will not descend, ordoes so slowly

• Motor not running

• Little or no hydraulic oil in the reservoir

• No oil supply to cylinder


• Hydraulic locking valve on power unit malfunctioning


• Hydraulic oil thickened due to low temperature

• Check Master Disconnect is "ON"

• Check that Circuit Breaker has not been tripped

• Check for shorts, ground faults or open circuits,e.g., power lines connected to the ground or a broken cable or connection

• In below freezing temperatures, check for frozen water accumulationin the motor housing

• Check motor solenoid. Replace if non-functional

• Check control switch. Replace if non-functional

• Fill with correct hydraulic fluid

• Check for any broken or blocked hoses, valves or filters




• Change to lower viscosity hydraulic oil


2. TROUBLE SHOOTING

18


2. TROUBLE SHOOTING

Liftgate will not descend, ordoes so slowly (cont.)

• Hydrauilic locking valve stuck

• Reduced hydraulic oil delivery to the cylinder

• Ground Fault

• Check for poor electrical connections

• Check voltage supply to motor. Minimum should be 10.5 volts under load. If voltage is too low, increase the power supply


• Check solenoid for proper operation

• Clean or replace control valve

• Check all hoses, connections and control valves; replace or service any faulty parts

• Check cylinder packing. Replace if necessary

• Check cylinder for scoring.Replace if necessary

• Clean or replace

• Check plunger assembly for proper adjustment

• Check for short circuit at valve pin

• Check for electrical short circuit.


Liftgate creeps down whilethe platform is in theunfolded position

• Leaks in thehydraulic system

• Worn lift cylinder(s)

• Hydraulic locking valve on power unit defective

• Electrical short circuit

19


Liftgate descends unevenly

Liftgate vibrates up anddown while lifting

• Defective flow controlvalve on passenger sidecylinder




• Air in system

• Tank breather is plugged

• Low pressure feed to pump is restricted

• Alternator/generator not working properly

• Frequent use with insufficient charging time

• Defective battery

• Defective pump motor

• Replace

• Replace

• Check for and remedy anydamage or obstruction in sliders, track or path of travel of platform

• Check function. Replace if non-functional

• Lower platform to ground and fill reservoir. Now raise and lower the platform several times. Refill reservoir if necessary

• Unplug breather

• Remove restriction

• Service or replace

• Check battery water level frequently

• Avoid use for frequent short periods without allowing adequate recharging time. Do not use liftgate with engine off

• Replace battery

• Replace motor


Excessive battery discharge

2. TROUBLE SHOOTING

20


2. TROUBLE SHOOTING

Overflowing throughreservoir breather

• Over filled reservoir

• Air in system

• Hydraulic system fault

• Orfice in fitting onopen/close cylinder isplugged

• Defective power unit

• Ground Fault

• Drain to proper volume

• Raise and lower the platform several times, refill if necessary

• Check hoses for kinks or sharp bends and reroute if necessary

• Check to make sure orifice is not blocked at POC cylinder end

• Check POC cylinder seals. Replace if defective

• Check valves on power unit for function

• Check electrical wiring for sufficient current (min. 10.5 volts) to valves

• Check electrical connections


• Check the ground from the chassis to the motor (minimum #4 battery cable)


Platform will not open orclose, or does so slowly

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Function: Short circuit protection; protects against abnormal amperage draw.

Trouble Shooting Symptoms: No 12 V current at control switch.

Test: When activated, 12 V DC on both terminals.

Replace: Disconnect positive and negative wire from battery terminals.Unbolt wires at terminals of switch - unbolt switch from box, replace, reinstall wires.

3. KEY ELECTRICAL COMPONENTS

3.1 Circuit Breaker – Part #20831

Function: A means of disconnecting the battery from the power unit. Also, a protection device against electrical fires, tampering, theft and battery drain.

Trouble Shooting Symptoms: Gate not working or working sluggish.

Test: When activated, 12 V DC on both terminals.

Replace: Disconnect positive and negative wire from battery terminals.Unbolt wires at terminals of switch - unbolt switch from box, replace, reinstall wires.

3.2 Master Disconnect Switch – Part #20450

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Function: When activated, switch provides high amperage power from the battery to the motor.

Trouble Shooting Symptoms: Motor not running when control switch is activated.

Test: If the switch vibrates or chatters,test he battery cable cominginto the liftgate for 12 volts. If there is a 12 volt reading, replace solenoid. If there is not a 12 volt reading, check the following:

Battery CableBatteryCharging System

Replace: To replace,disconnect positive and negative lead from the battery or turn the power off at the pump box using the master disconnect switch. Remove all wires. Remove the two bolts holding it onto the motor. Mount new Intermittent Duty Solenoid or Continuous Duty Tower Type Solenoid using bolts removed and replace wires.

3.3 Motor Solenoid – Part #25168

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Function: Used to operate the liftgate. Up/down.Transfers 12 V currentto motor start solenoid and to lowering valve and coil.

Trouble Shooting Symptoms: Gate not working when toggle pressed.

Test: Test Switch power at each terminal. Test should produce 12 VDC on common (black wire) without pressing button and 0 VDC on other side of the switch terminal. When the button ispressed, you should read 12 VDC on both sides of the terminals depending on direction of toggle.

Replace: To replace the toggle,loosen the nut on the neck of the toggle. Remove the cap on the tube. Pull the toggle out of the top or bottom. Disconnect the ring terminals from switch,reconnect ring terminals. Plug new switch in, run toggle backinto the tube, push the neck through the hole and fasten with nut.

3.4 Toggle Control for Up/Down Function – Part #68637

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3.5 Toggle Control for Up/Down Function – Part #68635

ILD Series Maintenance & Service Manual

4. KEY HYDRAULIC COMPONENTS

4.1 Hydraulic / Electric Schematic

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4.2 The Lift Cylinder Part # Description 68022 Cylinder, 2 ¼” Bore 68025 Cylinder, 2 ½” Bore 68027 Cylinder, 2 ¾” Bore

Function: The lift cylinder is a source of power. The lift cylinder has a chrome shaft. The seals are zero bypass which means that the cylinder will not drift down during operation.

Trouble Shooting Symptoms: Visible oil leaks coming from the shaft or internal leakage if one side lowers ½“or more in 15 minutes.

Test: Visible inspection with cover off - look for visible oil leaks coming from the cylinder.

Replace: 1. Lower platform to the ground. 2. Remove lower cylinder pin on both cylinders. 3. Run liftgate up until both cylinders are fully retracted. (Approx. 20

seconds) 4. Disconnect both hoses from top of defective cylinder. 5. Remove top cylinder pin and lift defective cylinder up and out of slider

and track. 6. Place new, fully retracted cylinder into lift and reattach top cylinder

pin. 7. Reattach all hoses to the new cylinder. 8. Fill hydraulic reservoir to ½” from top. 9. Activate the UP switch for 35 seconds. Wait 5 minutes activate the UP

switch for another 35 seconds. (70 seconds total) This will bleed the cylinders.

10. Activate the DOWN switch until the passenger side rod cross tube aligns with the lower cylinder mount hole in the slider.

11. Align rod cross tube with hole in slider, insert and reattach lower cylinder pin.

12. Repeat for driver’s side. 13. Make certain the all cylinder pins are fully inserted and secured with

retainers. 14. Run liftgate up and check that platform is level with threshold. If

platform raises out of level repeat step 9 to bleed the cylinder again. 26

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4.3 Pressure Compensated Flow Valve – Part #25180 (ILD35 & ILD44), #25181 (ILD55 & ILD66)

Function: Attached directly to port on power unit it controls the amountof oil that is released from the cylinder when the DOWNbutton is pressed. The valve compensates for the differentweights on the platform so that decent of the platform isalways constant. A problem exists if the platform comesdown faster when more weight is added.

Trouble Shooting Symptoms: Gate coming down at different speeds with different loads or platform lowers unevenly (passenger side of platform lowers faster than driver's side).

Test: Put load on platform - if gate comes down faster than without a load, replace valve.

Replace: To replace ,lower platform to the ground, unscrew hose, thenunscrew valve. When replacing new valve always make sure arrow on valve points toward the power unit. If you do not have a new adapter, remove the old one from theold valve and replace it on the new one. Reinstall valve, connect hoses and run through a few cycles to remove air from the system.

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4.4 Power Unit – Part #68030 (ILD35 & ILD44), #68839 (ILD55 & ILD66)

Function: Main function is to direct oil at the correct flow rate and pressure

Trouble Shooting Symptoms: Power unit not working.

Test: Test all individual components per instructions. Check powercable from battery to see if it is burnt, cut, or frayed.

Replace: Lower platform to the ground. Disconnect positive (+) lead and ground on the battery. Disconnect hose and electrical connections. Unbolt power unit. Put new unit in box and boltdown. Reconnect all electrical connections - connect batterycables. Energize pump until you get a straight stream ofhydraulic fluid coming out of the high pressure line.Reconnect high pressure hose. Run unit through two cycles.

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4.5 Check Valve Assembly – Part #68229

Function: The check valve prevents oil from returning back to the tank.It is the path the oil must take to get to the cylinder.

Trouble Shooting Symptoms: Platform drifts down without pressing down button.

Test: The motor is spinning backwards and the platform drops without any buttons pressed.

Replace: Check valves can only be cleaned. Lower platform to the ground, remove plug exposing spring and ball. Clean inside using a small brush to free any steel shaving that might be preventing the ball form seating properly. Clean spring and ball and replace. If symptom persists the Power Unit should be replaced.

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4.6 Adjustable Relief Valve Assembly – Part #68226

Function: Used to control the pressure the pump puts out. The standard operating pressure is 2600 PSI.

Trouble Shooting Symptoms: Gate not lifting the rated load.

Test: Pressure gauge in line with lifting hose should produce 2600 PSI.

Replace: To adjust pressure - remove hex cap to expose slotted screw. With gauge in line turn slotted screw clockwise until platform raises load or gauge reaches max. 2600 PSI. If at 2600 PSI gate cannot lift rated load consult factory.


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4.7 The Pump – Part #25140

Function: To displace fluid.

Trouble Shooting Symptoms: Gate not lifting or motor not spinning.

Test: Check all electrical connections for proper voltage. Inspect that hoses are not blocked. If motor spins when disconnected from pump but does not once it is connected, replace pump.

Replace: Power unit should be removed from box following instructions. Remove tank by unscrewing the 4 bolts holding it. Remove 2 bolts (11) holding pump to manifold when installing new pump it is recommended that a new filter (9) be installed. Install new pump (10) making sure shaft seal (7) on the pump is in place.


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4.8 Selector Coil and Valve – Part #68229

Function: Used to lower the platform to the ground. Oil travels through the valve when coil is energized with 12 VDC.

Trouble Shooting Symptoms: Platform not lowering when down button is pressed or platform drifting down on its own.

Test: 12 VDC at coil terminal when down button pressed. If you are getting 12 volts and nothing works - replace valve and coil.

Replace: To replace, lower the platform to the ground. Remove wire from valve terminal, remove nut on the end of the coil and slide coil out. Using a wrench, unscrew the valve from the Power Unit Body until it is free. Some oil still in the line will lleak out at this point, be prepared to catch it. Screw new valve in body tighten it to no more than 9 in. lbs./sq in. Replace new coil over valve and secure by hand tightening only the nut to the top of the valve. Replace wire on coil.Also check at cylinder.


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4.9 Motor – Part #25163

Function: Used to drive the pump, is linked by a spline connection to the pump. The motor has an end cap cover secured with two screws that can be removed for brush inspection and internal cleaning.

Trouble Shooting Symptoms: Motor not running.

Test: Test motor solenoid. If all is OK, pull motor only off pump and energize, if it does not run, replace. If it does your pumpis probably seized.

Replace: To change the motor ,remove end cap by removing the two screws on the end of the cap. Unscrew the hex head screwslocated on the brush holder and carefully pull motor off. Make sure spline connector (6) is on new motor shaft beforeconnecting new motor to pump. Reinsert and tighten hex head screw to secure motor. End cap should be reinstalled and secured.


“OPEN”Hydraulic/ElectricSchematic

How the ILD works

“Down”Hydraulic/ElectricSchematic

How the ILD works

“CLOSE”Hydraulic/ElectricSchematic

How the ILD works

“UP”Hydraulic/ElectricSchematic

How the ILD works



4.2 The Lift CylinderPart # Description68022 Cylinder, 2 ¼” Bore 68025 Cylinder, 2 ½” Bore 68027 Cylinder, 2 ¾” Bore

Function: The lift cylinder is a source of power. The lift cylinder has a chrome shaft. The seals are zero bypass which meansthat the cylinder will not drift down during operation.

Trouble Shooting Symptoms: Visible oil leaks coming from the shaft or internal leakage if one side lowers ½“or more in 15 minutes.

Test: Visible inspection with cover off - look for visible oil leakscoming from the cylinder.

Replace:1. Lower platform to the ground.2. Remove lower cylinder pin on both cylinders.3. Run liftgate up until both cylinders are fully retracted. (Approx. 20

seconds)4. Disconnect both hoses from top of defective cylinder.5. Remove top cylinder pin and lift defective cylinder up and out of slider

and track.6. Place new, fully retracted cylinder into lift and reattach top cylinder

pin.7. Reattach all hoses to the new cylinder.8. Fill hydraulic reservoir to ½” from top. 9. Activate the UP switch for 35 seconds. Wait 5 minutes activate the UP

switch for another 35 seconds. (70 seconds total) This will bleed the cylinders.

10. Activate the DOWN switch until the passenger side rod cross tubealigns with the lower cylinder mount hole in the slider.

11. Align rod cross tube with hole in slider, insert and reattach lower cylinder pin.

12. Repeat for driver’s side.13. Make certain the all cylinder pins are fully inserted and secured with

retainers.14. Run liftgate up and check that platform is level with threshold. If

platform raises out of level repeat step 9 to bleed the cylinder again.

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Supplement to ILD Cylinder Replacement Instructions for Passengers Side Cylinder Only

When replacing the passengers side cylinder on an ILD liftgate please note there is a pressure compensating flow control valve located at the top of the passengers side cylinder. Older models liftgates have external Pressure compensating flow valves, as seen in photo 1, and newer liftgates have internal flow valves as seen in photo 2.

Oactd OPi Iuco EnToi

1

n all 3500 lb and 4400 lb liftgates the inlready installed on your cylinder. You dontrol valve. Attach the hoses directly to he adaptor provided in the kit to screw irectly back to the adaptor on the cylinder.

n 5500 lb and 6600 lb models the flow colease note that on these models we h

ncorporate either pressure compensating v

nternal valve note: If you have the internase a 3/16 allen wrench to remove the old ylinder and insert it into the new cylinder. n the new cylinder.

xternal Valve note: With the external peed to use one of the adaptors provided he adapter used on the old cylinder mayne. Install the adapter provided in the

nstall the flow control and 3/8 JIC fitting on

Picture 2
Picture
ternal pressure compensating valve is o not need to install the external flow the 3/8 JIC fitting on the cylinder. Use into the cylinder and attach the hose

ntrol valve is not pre installed. ave provided fitting so that you can alve.

l compensating valve, you will need to pressure compensating valve from the Install the fittings from the old cylinder

ressure compensating valves you will in the kit to re-use the external valve. not be the same thread as the new

cylinder kit into the cylinder port and to the adapter. Reattach hoses.

ILD Closing Cylinder Bleeding Procedure

7/30/2007

1. Open Platform.

2. Lower Platform to 10” above the ground.

3. Remove pin retainer from lower closing cylinder pin.

4. Remove lower closing cylinder pin from cylinder and platform clevis.

5. Fully retract closing cylinder using switch.

6. Remove hose from upper fitting of closingcylinder.

7. Run fluid through hose by operating switchas if trying to close platform. (Run forapproximately 3 seconds)

Stop when fluid is exiting the hose in aclear stream.

8. Reattach hose to upper fitting of closingcylinder.

9. Fully extend closing cylinder using switch.Hold body of cylinder back while extendingto clear platform clevis.

10. Remove hose from lower fitting of closingcylinder.

11. Run fluid through hose by operating switchas if trying to open platform. (Run forapproximately 3 seconds)

Stop when fluid is exiting the hose in aclear stream.

12. Reattach hose to lower fitting of closingcylinder.

13. Align closing cylinder clevis with bracket onplatform.

14. Replace the lower closing cylinder pin and pin retainer.

15. Check pump fluid level. Fluid should be visable in tank site glass withplatofrm fully raised. Add fluid if needed.

Fully retractedwith lower pinremoved

Fully extendedwith lower pinremoved

Hold body ofcylinder backwhile extending

CHARGE LINE GROUNDING INSTRUCTIONS

1 of 1 11/6/2008

GROUND

INSTALLATION

INSTRUCTIONS

Trailer - Single Pole Socket …………….... page 1

Trailer - Dual Pole Socket (Preferred Method)… page 5

Truck Configuration……………………….. page 7


2 of 2 11/6/2008

Single Pole Socket Configuration

1. Determine ground type (External ground on plug or Ground through Fifth Wheel)

Tractor has external ground on plug: (Preferred Method) a. Drill 3/8” hole in passenger side aluminum side rail. Approximately 8” from front

of trailer. Remove plastic film then scuff and clean inside of aluminum side rail to remove oxidation.

b. Run #1 cable from side rail along front of trailer to single pole socket. c. Attach other end of #1 ground cable to a mount bolt on the single pole socket. d. Spray bolted connections with insulating varnish after bolting. e. In power unit box, attach ¼” terminal on 60” #1 ground cable to lock valve as

shown.

Lock valve

#1 ground cable

f. Route #1 cable through 7/8” hole on left hand side of box. Secure in 7/8” hole with grommet.

g. Run cable along power unit box frame to passenger side aluminum rail.

Cable run along power unit box frame

Secured in hole with grommet


3 of 3 11/6/2008

h. Drill 3/8” hole in aluminum side rail. Remove plastic film then scuff and clean

inside of aluminum side rail to remove oxidation. i. Attach 3/8” terminal on 60” #1 ground cable to aluminum side rail as shown.

Tractor Ground through Fifth Wheel: (Make sure Fifth Wheel is ground to batteries) a. Drill 3/8” hole in fifth wheel plate as shown (Approx. 4” in from side rail.) grind or

sand area around hole to bare steel. Make sure hole location will not interfere with movement of the fifth wheel.

b. Drill 3/8” hole in passenger side aluminum side rail. Remove plastic film then scuff and clean inside of aluminum side rail to remove oxidation.

c. Run #1 x 9” cable from fifth wheel plate and bolt to passenger side aluminum side rail.

Bolted to aluminum side rail Bolted to Fifth

Wheel plate

d. Spray bolted connections with insulating varnish after bolting.


4 of 4 11/6/2008

e. In power unit box, attach ¼” terminal on 60” #1 ground cable to lock valve as shown.

f. Route #1 cable through 7/8” hole on left hand side of box. Secure in 7/8” hole

with grommet. g. Run cable along power unit box frame to passenger side aluminum rail.

h. Drill 3/8” hole in aluminum side rail. Remove plastic film then scuff and clean

inside of aluminum side rail to remove oxidation. i. Attach 3/8” terminal on 60” #1 ground cable to aluminum side rail as shown.



Lock valve

#1 ground cable


5 of 5 11/6/2008

Dual Pole Socket Preferred Method - Run a direct ground cable along with charging cable from the

liftgate batteries to the dual pole socket. (2 gauge minimum)

Alternate method if separate ground cable is not available. a. Drill 3/8” hole in passenger side aluminum side rail. Approximately 8” from front

of trailer. Remove plastic film then scuff and clean inside of aluminum side rail to remove oxidation.

b. Run #1 cable from side rail along front of trailer to dual pole socket. c. Attach other end of #1 ground cable to ground terminal on dual pole socket. d. Spray bolted connections with insulating varnish after bolting. e. In power unit box, attach ¼” terminal on 60” #1 ground cable to lock valve as

shown.

Lock valve

#1 ground cable


6 of 6 11/6/2008

f. Route #1 cable through 7/8” hole on left hand side of box. Secure in 7/8” hole

with grommet. g. Run cable along power unit box frame to passenger side aluminum rail.

h. Drill 3/8” hole in aluminum side rail. Remove plastic film then scuff and clean inside of aluminum side rail to remove oxidation.

i. Attach 3/8” terminal on 60” #1 ground cable to aluminum side rail as shown.




7 of 7 11/6/2008

Straight Truck Configuration

a. Make sure truck starting batteries are grounded to chassis. (Ground may have been provided by truck manufacturer.)

b. If needed, drill 3/8” hole in chassis as close to batteries as possible. Grind or sand area around hole to bare steel.

c. Run #1 cable from chassis to negative terminal on batteries.

Ground to chassis

Ground to batteries

d. Spray bolted connections with insulating varnish after bolting. e. In power unit box, attach ¼” terminal on 60” #1 ground cable to lock valve as

shown.

Lock valve

#1 ground cable

f. Route #1 cable through 7/8” hole on left hand side of box. Secure in 7/8” hole with grommet.

g. Run cable along power unit box frame to truck chassis. h. Drill 3/8” hole in chassis. Grind or sand area around hole to bare steel. i. Attach 3/8” terminal on 60” #1 ground cable to chassis as shown.

Ground from power unit box to chassis

j. Spray bolted connections with insulating varnish after bolting.

ILD TROUBLE SHOOTING & PARTS Interlift Inc.a member of MBB

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Transcript of ILD TROUBLE SHOOTING & PARTS Interlift Inc.a member of MBB