INTERLIFT

ILR INSTALLATION MANUAL

& CHECK-OFF SHEET INTERLIFT, INC. a member of MBB

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

Visit out 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

TABLE OF CONTENT Page Dimension Sheet

3

Important Notes

4

Frame Cut Out Dimensions

5-6

Chassis and Body Prep – Platform Installation

7

Gate Installation

7-10

Electric & Hydraulic

10-11

Electric Schematic

12

Hydraulic Schematic

13

Decal Placement

14

Service Bulletin

15

Recommended Tools For Installation

Metric Wrench Set Basic Screwdrivers Pliers Wire Crimp Pliers Test Light Snap Ring Pliers Hammer Metric Allen Set 1.5mm-10mm ½” Impact & Sockets Sm. Metric Socket Set Assorted Drill Bits Floor Jack or Equiv. Sm. To Med. Bottle Jack Forklift or O/H Crane Hand Held Grinder Paint Gun Pry Bar 3/8 Drill Motor Heat Gun or Equiv. Min. 250 Amp Welder Cutting Torch or Equiv.

2

3

Company:

Liftgate Type:

Type of Body: ............. Van, ..........FlatbedType of rear door:..........Roll-up, ............Swing, ............Flip-up

A= bedheight...........B= Top of floor to bottom

of frame.........

C= R

ear sill height...........D

= Spring hanger to end of body...........E= Tire to end of body..........F= G

as tank to end of body..........G

= Bottom of fram

e to bottom of gas tank........

AB

C

DE

Please fax information to Interlift (562) 924-8318

F

Truck Make.................G

VWR...............

G Chassis Dimension Sheet

Fill out and send to Interlift if specific Install darwing is needed

4

Important Notes:

1. Read Manual completely before beginning any work 2. Refer to your truck manufacture’s instructions before adding any auxiliary equipment.

3. Pay Special attention to items marked with this symbol 4. All welding should be performed by qualified personnel per AWS standards 5. Always Ground closest to your welding point to prevent arcing through moving parts 6. Contact Interlift, Inc. for Special Installation not covered in this Installation Manual 7. Do Not Paint Cylinder Shafts or Nylon Rollers (Use Non-Chlorinated Brake Cleaner to

remove over spray) 8. Verify Pin Bolts are tight 9. Grease all pivot points 10. Verify ALL Decals properly placed (Contact Interlift to replace any missing decals) 11. Final Check Off Sheet at rear of this Manual MUST be filled out and kept in your

records for future reference. 12. Refer to Owner’s Manual for Troubleshooting & Repairs.

Important Dimensions: (Refer to line drawing on following pages)

BED HEIGHT [H] Bed Height Ranges: Max=Unloaded / Min=Loaded Truck

• Measure from top of body floor to ground. Vehicle must be on flat level ground when measured.

MOUNT TUBE HEIGHT [F] • Measure from TOP of Mount Tube to TOP of body floor

Mounting Notes: Important!!! Interlift Liftgate’s are simple yet versatile in their installation The basic rule of Interlift ILR installation is to lift mount frame to achieve MINIMUM “F” dimension (17”) WITHOUT exceeding Min/Max ground clearance. (14”/19-1/2”) Note Increase “F” dimension to maintain max ground clearance on higher bed heights installations Call tech support before fully welding if you have any questions or concerns on mounting dimensions – 888-774-5844 x17

Platform Channel Stop

To simplify installation Interlift provides you with a "Stop Channel" in placeof trimming and capping the frame rails to fit each particular floor height

38" Thru 45" Bed Heights

46" Thru 54" Bed Heights

1. After installation of gate assembly, raise gate until liftarms contact stop angles or rear sill.2. Place platform channel stop along chassis frame and set edge onto platform as shown(one side only)3. Weld into place

Stop Angle

Platform Stop Channel

Frame Preperation and Platform Stop

20.13"

10.39"

17.78"

14.53"

Bed Height Ranges: Max=Unloaded Truck/Min=Loaded

5

F

Mount Clearance

Ground ClearanceMin. 14"Max. 19-1/2"

Installation Dimension Table

Min. 17"Max. 29-1/2"

End of Body to Front of Mount Plate

Min. 24"Max. 35"

NEVER exceed any of the following dimensions

Mounting dimensions Top of floor to

Top of mount frame ILR (800 mm) arm, 42" &

48” platform End of body to forward edge of

mount plates Bed Height F-Dimension Ground Clearance Mount Clearance 38” to 54” 17 to 29-1/2” 14” to 19-1/2” 24” to 35”

Dimensions F, Mount Clearance and Ground Clearance always follow each other

Important!!! Interlift Liftgate’s are simple yet versatile in their installation The basic rule of Interlift ILR installation is to lift mount frame to achieve MINIMUM “F” dimension (17”) WITHOUT exceeding Min/Max ground clearance. (14”/19-1/2”) Note Increase “F” dimension to maintain max ground clearance on higher bed heights installations Call tech support before fully welding if you have any questions or concerns on mounting dimensions – 562-924-8218 x17

6

Chassis and Body Prep

1. Determine the correct frame cut out according to your specific bed height and amount of overhang on truck. Refer to pages 4

2. Trim longsill, subwood & chassis frame per pages 4 3. Trim bed extension 1” shorter than overall width of body (½” each end)

Trim both ends equally 4. Tack weld or clamp remnant channels (2) or equiv. to rear sill (not supplied) 5. Center bed extension on rear sill, flush with floor. (Fig. 1) 6. Clamp to remnant channels (2) or equiv. 7. Weld using 9 fillet @ 3” x 3/16” minimum alternating top and bottom 8. Install dock bumpers (if applicable) (available from Interlift separately) 9. If installing Interlift dock bumpers refer to Fig. 2

Remnant Channel or Equiv.

Bed Extension

Tach Weld Or ClampTo Rear SillClamp To Hold In Place

9x4"9x4"

3/16"3/16"

Do NOT weld along vertical posts on van install. Always start at opening

Gusset Hole

3" Channel"A"

(Customer Must Miter Per Application)

Channels Shipped W/ Sq. Ends

"A""A"

Bed Height Bumper44" and Above 24"43" and Below 20"

Note:20" Bumpers Have Single Step Opening

11"

12"

Fig. 1 Fig. 2

Gate Installation Without Platform Attached (recommended)

1. Raise gate assy (without platform attached) to align upper liftarm bushings with bed extension gusset holes (Fig. 1)

2. Insert upper liftarm pins through upper liftarm bushings and gusset holes 3. Using floor jack or equiv. swing frame assy up as high as possible staying within “F”

dimension/ground clearance ranges per page 6, Fig. 6 and notes 4. Use second jack to level rollover wheel if necessary. 5. Install mount plates and tack weld using 2 fillet welds 2” long on each side and top of

mount plate to frame and at mount plate to mount frame location 6. Connect battery cable to truck battery, aux battery, or temporary battery

(Ref. Page 12) 7. Remove pins and lower liftarms to allow for platform installation

7

Platform Installation (Fig. 3&4) 1. Slide pins out to clear liftarm clevis (closest to center of platform)

Do not slide so far that shackle or spring fall out 2. Lift platform to liftarms with forklift or equiv. 3. Align liftarms into clevises and drive pin until pin tab seats in pin tab hole and install

pin bolt and tighten to 14 ft-lbs 4. Verify coil spring is positioned properly

Note: 48” Platform has coil springs on each arm 42” Platform has one coil spring

Gate Installation With Platform Attached

Short leg against tab

Curb Side LOOKING Rear

Liftarm Clevis

Shackle

Verify contact is backsideof winding direction

Shim 1/4" if needed

Fig. 3 Fig. 4

Never work under platform without safety supports 8. Install platform per Platform Installation above.

Shackle MUST be in contact with platform adjusting bolt throughout install 9. Raise gate assy by platform using forklift, overhead crane or equiv. and mate front

edge of platform to back edge of bed extension leaving approx. 3/16 gap. 10. Clamp or tack weld platform to bed extension (platform should be parallel to floor) 11. Using floor jack or equiv. swing frame assy up to proper “F” dimension per page 6,

Fig. 6 and notes 12. Use second jack to level rollover wheel if necessary. 13. Verify that the 2 shop applied tack welds at the platform/shackle are secure. 14. Install mount plates and tack weld using 2 fillet welds 2” long on each side and top of

mount plate to frame and at mount plate to mount frame location 15. While supporting platform with forklift, overhead crane or equiv. remove installer

applied tack welds from platform to shackle. 16. Connect battery cable to truck battery, aux battery, or temporary battery

(Ref. Page 12) 17. Cycle gate several times to assure proper alignment.

Do not power gate hard against bed extension while gate is only tack welded in position

8

18. Complete welding of gate. Weld all contact areas 100% with ¼” fillet or butt welds. 19. Verify platform lowers smoothly without hanging up on wheel. 20. Install platform channel stops per page 4 and Fig. 7 (one side only)

Verify Safety Chain And Hook Latch To Platform Handle

Remnant Channel or Equiv.

Tach Weld Or ClampTo Bed Ext.Clamp To Hold In Place

ShacklePlatform Adjusting bolt

Fig. 5

+1-1/2" to -1/2"

Mount Plate

1/4"1/4"

Min. 6" Weld Overlap

1/4" x 18" total

Fig. 6

9

Set channel to contactplatform when closed

It is acceptible for platform to stop on rear sill of truck rather than

frame cap or bed extension stops

Arms DO NOT have to contact stops when closed if platform contacts frame cap or sill

Platform channel stop neededon ONE SIDE ONLY

Shut Off

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

Fig. 7 Fig. 8

PLATFORM LEVELING AND ADJUSTMENT 1. Lower platform until shackles contacts ground 2. Adjust bolts so tip of platform is ¼” from ground (Fig. 5) 3. Tighten jam nut

Note: Some minimum bed height installations may result in a slight downward incline of platform at bed level

ELECTRICAL AND HYDRAULIC INSTALLATION When performing electrical and hydraulic installation, please be certain to install and secure everything in a way where it is not subject to damage from moving parts, sharp edges, exhaust systems, etc. 1. Determine location for fixed toggle switch on corner post in a way that the operator can

view the platform and surrounding areas while operating the liftgate. (Fig. 9) 2. Install Liftgate On/Off Switch in truck or at rear of trailer in clear view of driver (Fig. 10)

When Supplied, Liftgate On/Off Switch MUST be installed and in clear view of driver. 3. Install the battery cable between power pack and battery. Connect the power cable for the

gate to the positive terminal on the battery. Secure the cable every 12 inches against the frame with frame clips. Never secure cable in a way where it can make contact with other wiring, brake fuel or airlines etc or get pinched against other objects.

4. Inspect and test all electrical connections, wiring and the different functions to make sure that the electrical installation is complete.

10

LOCATE EXISTING WIRE ON GATE FOR REMOTE CONTROL: 1. Find hot wire & touch hot wire to other wires. 2. Note Function and match below.

2 Button Hand Control

UP - 5 - RED DOWN - 6 - YELLOW

12V HOT - 4 - GREEN

Rear Vertical Body Post

Raise/Lower Switch

Sleeves (2)

#10x1-1/2" Self Drilling Pan Head (2)

M B B

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

MUST BE HAND TIGHTENED

ø 7/8"

Swing Door/Optional Up/Down Switch Location(Cup Mount Sold Separately)

Typical Trailer On/Off Installation

Corner Post

Fig. 9 Fig. 10

11

12

(-)

12 Volt Power Supply To C

ontrols

Thermal Switch

To Battery/Fuse/Breaker

#5UP

#6DN#4

#5

#6

#15

Ground (-)

#4

#4#5

#6

#4#5

#6

#3#3

#3

#3

#2

#2#2

#4

(-)

(-)

(-)

Spare

Ground (-)

Ground (-)

FusesO

ne used for #2O

ne spare

Cab Switch

Hand Control(If Applicable)

Lift Cylinder

Up/Down Toggle

Junction Box(Tied to m

ount tube)

Ground (-)

PlugSocket

(+)(-)

Solenoid

(+)

M

R1

PressureRelief Valve(2850 PSI)200 Bar

Flow Divider

PressurePort

S1

ILRHydraulic SchematicS1 release valve for down function R1 restrictor valves at cylinder port, before the hoses

13

14

15

SSEERRVVIICCEE BBUULLLLEETTIINN

FFOORRDD FF –– TTYYPPEE CCHHAASSSSIIEE

FORD FACTORY TERMINAL ON POSITIVE AND NEGATIVE BATTERY POST. SOME TRUCKS HAVE A TERMINAL MADE OF STAMPED SHEET METAL AND DO NOT HAVE ENOUGH ROOM FOR LIFTGATE CABLE LUG. THESE TERMINALS MUST BE CHANGED TO A MARINE TYPE TERMINAL (VELVAC P/N 058019). IT IS ALSO IMPORTANT TO CHECK GROUND CABLE FROM BATTERY. IF GROUND CABLE IS ATTACHED TO MOTOR, THEN, A SEPARATE GROUND CABLE MUST BE ADDED TO TRUCK FRAME.