interlift - palfinger...interlift ilm installation manual & check-off sheet rev. 1.4 , date...

INTERLIFT

ILM INSTALLATION MANUAL

& CHECK-OFF SHEET Rev. 1.4 , Date 08-01-2011

INTERLIFT, INC. dba MBB Palfinger

15939 Piuma Ave., Cerritos, CA 90703 Tel (888)-774-5844 Fax (562)-924-8318

572 Whitehead Road, Trenton, NJ 08619 Tel (609)-587-4200 Fax (609)-587-4201

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

If you received this product with damaged or missing parts,

Please contact Interlift, Inc. at (888)-774-5844

http://www.interlift.net/

ILM Plus Installation Manual

Revision 1.4

Table of Contents

Table of Content Page 2

Safety Information Page 3

Important Information Page 4

Tools for Installation Page 5

Mounting Requirements Pages 6 to 9

Body Preperation Pages 10 to 14

Liftgate Preperation Page 15

Position Liftgate Pages 16 to 17

Welding Liftgate Page 18

Installation of Bracket for Control Unit Page 19

Battery Cable Connections Page 20

Basic Wiring (manual closing) Page 21

Basic Wiring (power closing) Page 22

Decal Kit Page 23

Decal Placement Page 24

Cycle Test and Bleed Hydraulic System Page 25 to 26

Final Inspection Check List Page 27


Revision 1.4

Safety Information This manual follows the Guidelines set forth in “ANSI Z535.4-2007” for alerting you to possible hazards and their potential severity.

This is the safety alert symbol. It is used to alert you to potential personal injury hazards. Obey all safety messages that follow this symbol to avoid possible injury or death.

! DANGER indicates an imminently hazardous situation which, if not avoided, will result in death or serious injury.

! WARNING indicates potentially hazardous situation which, if not avoided, could result in death or serious injury.

! CAUTION indicates a potentially hazardous situation which, if not avoided, may result minor or moderate injury.

CAUTION without the safety alert symbol is used to address practices not related to personal injury. (In this manual we use it to alert you to potentially hazardous situation which, if not avoided, may result in property damage.)

NOTICE without the safety alert symbol is used to address practices not related to personal injury. (In this manual we use it to alert you to special instructions, steps, or procedures.)


Revision 1.4

Important Information

Before Getting Started

“READ FIRST”

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

Read and understand the “Installation Manual” and “Owners Manual” in their entirety before starting your Installation.

Refer to your truck manufacture’s instructions before adding any auxiliary equipment.

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

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

Contact MBB Interlift for Special Installations not covered in this Installation Manual.

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

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

Verify that ALL decals are placed properly. (Contact MBB Interlift to replace any missing decals)

Refer to owner’s manual for operation and maintenance information.


Revision 1.4

Tools for Installation The list of tools representative of the typical tools required to install liftgates.

250/300 amp MIG Welder

Forklift or Overhead Crane

Cutting Torch, Plasma, or equivalent

3 Ton Floor Jack

2 Ton Bottle Jack

Portable Hand Drill

Assorted Drill Set

Portable Hand Grinder

Paint Gun & Accessories

SAE & Metric Wrench Set

SAE & Metric Socket Sets

SAE & Metric Allen Wrench Set

½” Impact Socket Set

Test Light

30” Pry Bar

Screwdriver Set

Assorted Pliers

Assorted Hammers

Snap Ring Pliers

Heat Gun


Revision 1.4

Mounting Requirements

Minimum Bed Height dimensions are ALWAYS MAXIMUM LOADED TRUCK. Maximum Bed Height dimensions are ALWAYS DRY UNLOADED TRUCK. Ensure truck body or trailer rear door does not interfere with installation or operation of liftgate ILM plus series liftgate. The ILM plus series cannot be installed with "barn" or "swing" type doors without extensive modification. It is not recommended to cut, torch, or remove support materials from rear sill of truck or trailer. Installers are advised to sub-frame or flush sills as required. Removing gussets, stiffeners, light rings, or other such support structures may VOID your truck/trailer warranty. Call MBB Interlift tech support before starting the installation if you have any questions or concerns on mounting dimensions or procedures… 888-774-5844


Revision 1.4

Mounting Requirements

Step 1 Measure Floor Height and determine clearance requirements for your liftgate platform size. Step 2 Check chart below to ensure that your gate is compatible with bed height of the vehicle.

ILM plus Dock Loading Bed Height Chart

Platform Depth Dock Loading Bed Height Range

Min. Max.

NO Dock Loading Bed Height Range

Min. Max.

30”+ Folding 35” 54” 30” 54”

30”+ 6” 39” 54” 30” 54”

36”+ Folding 41” 54” 30” 54”

36”+ 6” 45” 54” 30” 54”

42”+ Folding 47” 54” 30” 54”

42” + 6” 51” 54” 30” 54”

Max Bed Height 54"

Standard 52"

Above Floor 57"

Ground Clearence 18"

3" Column

10" Max

6" Box

Floor/Bed Height


Revision 1.4

Mounting Requirements Step 3 Determine body side wall, corner post, and rear sill strength requirements.

Truck body or trailer must be capable of supporting minimum forces and loads shown below.

Z

Z

Y

Y

X

X

Side Wall Requirements Chart

ILM 16 ILM 20 ILM 25 ILM 30

X = Side Wall Tension 1000 lbs. 1200 lbs. 1500 lbs. 1800 lbs.

Y = Side Wall Compression 1000 lbs. 1200 lbs. 1500 lbs. 1800 lbs.

Z = Side Wall Shear 1300 lbs. 1500 lbs. 1800 lbs. 2000 lbs.


Revision 1.4

Mounting Requirements Step 4 Determine liftgate width requirements The ILM plus series liftgate is offered in three widths for most standard bodies. Standard 94” OD for 96” wide bodies. (most common) Optional 100” OD for 102” wide bodies. Optional 88” OD for 90” wide bodies

Nominal Truck or Trailer Width

Liftgate Outside Frame

Liftgate Inside Frame

Liftgate Platform Width

90” Wide Body 88” 82” 82”

96” Wide Body 94” 88” 88”

102” Wide Body 100” 94” 94”

Outside Frame Width

Inside Frame Width

5" Sprocket Box

52"

5"

18"


Revision 1.4

Body Preparation Step 1 Remove any sill or corner post mounted lights, grab handles, or bumpers. Your goal is to have a flat and flush mounting surface for the liftgate. Truck and trailers applications with flush corner post and sill and NO protruding gussets or stiffeners are the most straight forward of all ILD installations. Rear of body should be 90` to ground as shown.

It is not recommended to cut, torch, or remove support materials from rear sill of truck or trailer. Installers are advised to sub-frame or flush sills as required. Removing gussets, stiffeners, light rings, or other such support structures may VOID your truck body or trailer warranty. Step 2 Be certain that under ride bumpers, trailer hitches, or other auxiliary equipment do not extend rearward of rear sill. Use the following illustrations as a guide.

Bed LevelRear Sill

Rear BumperNeeds to be mounted Flush with Sill.

Rear Sill

Bed LevelRear Sill

90°

Rear BumperFlush with sill.


Revision 1.4

Body Preparation Step 3 Trailer Hitches are common truck or trailer equipment and are compatible the ILM plus series. Two considerations for mounting or moving are… Hitch can NOT extend rearward of rear sill and liftgate will extend rearward an additional ??????”.

Bed LevelRear Sill

Hitch or other Equipment must NOTextend rearward of rear sill.


Revision 1.4

Body Preparation Step 4 Some trucks or trailers may have configurations with irregular shaped sills. Liftgate mounting surface may NOT be flush with corner post. Some sills may be inset or have door gutters. All these situations are remedied with a process called sub-framing and/or flushing the sill. Sub-framing is done one of two ways; Sub-frame can be built up using correct size 3/16” or greater wall tubing before liftgate is mounted. Or, the liftgate can be mounted into position and sub-frame can be built as liftgate is installed with 3/16” or greater flat bar. In either case, liftgate installation weld procedure does not change. These examples are show below. Flushing floor or filling gap between Sill and liftgate can be done up to 6” without cross supports. Use ¼” or greater flat bar or diamond plate to span gap.

Bed Level Corner Stiffener

Light Box

Corner Post

Liftgate Mounting Surface

Liftgate Platform Surface

Gap between Sill and Liftgate

Corner Post

Sub-Frame

Liftgate

Corner Post

Sub-Frame Flat Bar

Liftgate

Tubing sub-frame Flat Bar sub-frame


Revision 1.4

Body Preparation Step 5 Corner stiffeners are common and should NOT be removed. It is recommended to “flat bar” with same thickness as stiffener. Typically ¼” to 3/8” thick x 3” wide. Liftgate Installation weld procedure is the same.

Corner Stiffener

Corner Stiffener

Flat Bar

Flat Bar

Flat Bar


Revision 1.4

Body Preparation Step 6 Side supports can be used to strengthen body. Refer to Mounting Requirements Step 3. Step 7 Flat bed installation may use similar arrangement with 3/16” x 4” x 4” Min. tubing for corner post and 3” channel for support bar.

72"

Approx. 60"

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

1/4" x 100% weld each end

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

of body cross member.


Revision 1.4

Liftgate Preparation Step 1 Remove shipping ties from all electrical harnesses and position so NOT to interfere with position of liftgate to body or welding processes. Step 2 Lower shipping feet may have to be removed for installation on some deep sills. Step 3 Weld two (2) supports to cross beam. This will help ensure even alignment between liftgate crossbeam and body sill. Use 3” angle or channel approx 10” long.

Steps 2 & 3 are best done with liftgate hoisted with forklift or crane. This brings items to be addressed to working level.

Never position any portion of body under liftgate.


Revision 1.4

Positioning Liftgate

Before positioning the liftgate. Consider when measuring and centering the liftgate that the truck or trailer may NOT be square or parallel. Special care must be taken to insure that the liftgate is square and parallel before welding. Step 1 Truck should be on level and even ground. Uneven ground will give misleading measurements and can cause body twist or racking. Step 2 Preferred method for lifting liftgate is with a forklift. Position forks to widest point and lift from center. 12” or larger “C” or “F” style clamps can be used to coach or hold liftgate in position. Step 3 Use 4”x 4” x 24” wood spacers as shown. This will help force top of liftgate tight against body for welding. Should you need to force bottom portion, remove wood spacer and use the forklift against the lower portion of liftgate. Step 4 Preferred method for centering liftgate is measuring side clearances from outside of liftgate to outside of body. (centerline marked on sill is NOT easily visible.) Step 5 Verify all mounting dimensions, double check that floor and threshold extension are flush.

Never remove lifting device until liftgate is fully welded.

Floor/Bed Height

90°

Forklift Not Shown

Support Channel

Forks

4x4x24 Wood Block


Revision 1.4

Positioning Liftgate Step 6 Check liftgate to be certain it is square and parallel. Use a 3 ft carpenters square to check column to threshold. Step 7 Use to “Dim A” and “Dim B” to verify columns are parallel. Step 8 Use “Dim C” and “Dim D” to verify columns are square. Step 9 Check that columns are also 90 degrees to sill or body.

DO NOT WELD until all dimensions are checked and rechecked after each positioning adjustment.

Dim "A"

Dim "B"

Dim "C" Dim "D"


Revision 1.4

Welding Liftgate Step 1 Using 3/16” x 2” welds, place one weld ½” from the top of each column on the outside and place one weld at the bottom of body.

STOP and recheck all mounting dimensions from “Position Liftgate” section. Step 2 Weld inside of column 3/16” x 2” x 4 places evenly spaced top to bottom. Step 3 Weld inside of floor 3/16” x 2” x 5 places evenly spaced left to right. Step 4 Final welding outside of column 3/16” x 2” x 5 places evenly spaced.

Outside Column 3/16” x 2” weld 6 places as shown.

Inside Column 3/16” x 2” weld 4 places as shown.

Inside Floor 3/16” x 2” weld 5 places as shown.

On “Power Closing” liftgates. Inside hose guard must be removed for proper welding of inside of column. Take special

care not to burn hose.


Revision 1.4

Tools: Rivet gun, wrench

Position of lift gate: In stored position

Time: 10-15 min

Pic. 1: Bracket Mounting (ILM+)

Upper Mounting Position (4 long rivets)

Lower Mounting Position (4 short rivets)

Sleeve (3 short rivets)

Installation of Bracket for Control Unit see pic. 1

Step-by-step: -Disconnect lift gate power cable at battery • Mount bracket for control unit at lift gate column (curb side) with four rivets. For

trucks with a bed height from 46” to 54” use the lower mounting position and short rivets, for trucks with a bed height of 46” or less use the upper mounting position and long rivets (see pic. 1). Install rivets with rivet gun

• Now Install control unit to bracket, cable has to face to the ground. Mount control unit with bolt at bracket

• Install cable sleeve at column with short rivets, for higher bracket position use three upper holes, for lower position use three lower holes (see pic. 1)

• Connect battery cable • Operate gate, check functions


Revision 1.4

Battery Cable Connections

Take care not to route hoses, wires, harnesses, and cables near, around, or in contact with sharp edges, air lines, vehicle electrical, exhaust system or fuel lines.

The ILM liftgate is a industrial hydraulic lifting device. Performance and reliability are closely related to proper installation, battery cable connections, and grounding. All grounding surfaces MUST be cleaned, prepped, and sealed per this manual. “Cut to size” cables MUST be properly crimped and sealed as factory supplied. All connection MUST be dressed with dielectric grease or equivalent sealer. Step 1 Check for 2 gauge ground cable or heavier connecting truck batteries to chassis. If NOT supplied by the manufacturer, one will need to be installed. Be sure to grind off paint or under coat and seal. Step 2 Route battery cable to truck batteries and secure with clips and ties supplied. Step 3 Install 150 amp circuit breaker at battery location and use 12” cable to connect to positive terminal.


Revision 1.4

Basic Wiring (Manual Closing)

25 F

t. x

4 G

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Cable

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Starter - Green

Lower - Black

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Revision 1.4

BASIC WIRING (Power Closing)

25 F

t. x

4 G

a. B

attery

Cable

Power - Red

Raise - Green

Closer - White

Lower - Black

Low

er

Sole

noid

Gro

und -

Clo

ser

Sole

noid

- B

lack

Gro

und -

Low

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lack

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- B

lack

Clo

sing S

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4 G

a. B

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Cable

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12"

x 4 g

a. B

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To T

ruck

Battery

150 a

mp

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Revision 1.4

Decal Placement and Inspection

For operator’s safety, all decals appearing in “Decal Kit” must be in a conspicuous place on control side of liftgate to be read by operator. This is typically a combination of decals on the liftgate and truck body. Please make sure to place the maximum capacity decal (C) on driver and curb side. (A) 1 ATG-OPERILM ML/PC - Operating Instructions

(B) 1 ATG- SWILM MC/PC - Main Operation Switch

(C) 2 ATG-XXXX - Max. Capacity (please check the serial number plate to find out your

specific capacity)

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

(E) 1 2 ATG-WLH - Warning: liftgate can crush

(F) 2 ATG-CTN - Caution: Always stand clear of platform area

(G) 1 ATG-RESET - Circuit Breaker Protection

(H) 1 ATG-BKR - Circuit Breaker Reset (must be located at the circuit breaker)

(J) 1 ATG-CAB - Liftgate Shut-Off (must be placed next to the Shut-Off Switch)

(K) 1 ATG-UD - Toggle Decal (only if applicable)

(L) 1 ATG-ILMSTORAGE – Storage Latch

Decal A

Version A

Decal – B

Version B

Decal - C

Decal - G

Decal - H Decal - J

Decal - E

Decal - F

Decal - D

Decal - L

Decal – B

Version A

Decal – A

Version B

Decal - K

Decal - E


Revision 1.4

Figure 1: Decal Placement Guideline

Decal B

Decal C (at both sides)

Decal A

Decal G

Decal D

Decal E (at both sides)

Decal L

Decal F (at both sides)


Revision 1.4

Cycle Test and Bleed the hydraulic system.

Improper use of the liftgate may result in serious injury. DO NOT operate this liftgate without being properly instructed and fully understanding the Owners manual. Platform may crush or pinch. Make certain area around liftgate is clear during all times of operation.

No bleeding of hydraulic required. System is self bleeding system and is pre-bled from the factory. Test steps a minimum of five (5) times each to ensure NO unusual noises or movements are found. This will confirm all controls work correctly and hydraulic system is completely bled of air.

POWER CLOSING Switch Operations for “Power Closing”

“UP” switch raises platform from ground to bed.

“DOWN” switch lowers platform from bed to ground.

“SHIFT” + “UP” closes platform from loading position to stored position.

“SHIFT” + “DOWN” opens platform from stored position to loading position. Storage and Transit Position “Power Closing”

Platform is closed and stored UP tight into the storage latch with hydraulic power.

Pad lock is used on safety latch to prevent unauthorized use.

Never release platform on to safety latch. This latch is for EMERGENCY situations ONLY. Platform from Stored Position to Loading position “Power Closing”

Be certain all pinch points and areas around platform are clear before operating liftgate.

Hold safety latch to the open position and push “DOWN” button until platform clears storage latching system.

With platform clear of latching system, hold “SHIFT” button & push “DOWN” button to open platform to loading position.

Platform from Loading Position to Stored Position “Power Closing”


With platform in the loading position, hold “SHIFT” button & push “UP” button until platform touches striker pads.

With platform folded up and touching striker pads, push “UP” button until platform is powered tight into storage latch.

Never release platform on to safety latch. This latch is for EMERGENCY situations ONLY.


Revision 1.4

MANUAL CLOSING Switch Operations “Manual Closing”

“UP” switch raises platform from ground to bed.

“DOWN” switch lowers platform from bed to ground. Storage and Transit Position “Manual Closing”

Platform is closed and stored tight into the storage latch with hydraulic power.

Pad lock is used on safety latch to prevent unauthorized use.

Never release platform on to safety latch. This latch is for EMERGENCY situations ONLY. Platform from Stored Position to Loading position “Manual Closing”


Hold safety latch to the open position and push “DOWN” button until platform clears storage latching system.

With platform clear of latching system, and positioned to firmly grasp ramp end, pull platform towards ground.

Platform from Loading Position to Stored Position “Manual Closing”


With platform in the loading position, and positioned just above knee height, firmly grasp ramp end and pull up closing until platform touches striker pads.

With platform folded up and touching striker pads, push “UP” button until platform is powered tight into storage latch.

Never release platform on to safety latch. This latch is for EMERGENCY situations ONLY.


Revision 1.4

Final Inspection Check List

Liftgate failure or malfunction could result in property damage, personal injury or death if you fail to check each of the following items listed. DO NOT USE the liftgate if any of the following points are NOT verified and checked.

Installation is NOT complete and all WARRANTIES are VOID if you have not checked and verified all items listed on this inspection sheet. Inspection sheet is to be filed at the facility where liftgate was installed. Structural Inspection

Lifting bar and shipping feet are removed from the liftgate.

All welds are 100% complete per this manual.

All nuts, bolts, mounting hardware, pins, chain anchors are tight.

All mounting dimensions are correct and liftgate is square and parallel per this manual. Hydraulic Inspection

Pump reservoir is filled to 1" from top when platform is fully raised to truck floor.

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

All hydraulic lines are secured with cable ties, hoses clamps, or other fasteners. Electrical Inspection

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

All electrical lines are secured with cable ties, hoses clamps, or other fasteners.

Circuit Breakers installed and wired per instructions.

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

All decals are in place and legible per instructions.

All pivot points are lubricated per instructions.

Platform secures properly in its stowed position latches.

Platform powers UP and locks hydraulically in latches.

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

Platform is level with the floor of the vehicle when raised completely.

Platform rests on the ground evenly when lowered completely.

Platform opens and closes properly and at correct speed. (2 to 4 inches per second)

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

Owners Manual is in the vehicle's glove box.

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: _____________________

interlift - palfinger...interlift ilm installation manual & check-off sheet rev. 1.4 , date...

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