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3. ILD Series Maintenance amp Service Manual ILD Series Liftgate gt A Lift Cylinder Column Column Left Hand Right Hand Slider Wear Pads gt N Hydraulic A Open amp Close Su l cylinder LeftHand 4 Inner Section Platform Outer Section Platform Hinge Pin Platform ILD Series Maintenance amp Service Manual Design Detail Power System Lift Cylinder Flow Control Valve Control Switch Assembly 12 Volt Power Supply Power Unit ILD Series Maintenance amp Service Manual 1 PREVENTIVE MAINTENANCE We strongly recommend that operators use our preventive maintenance schedule as a means of keeping their liftgate running at its best We recommend that the Daily Overall Inspection should be performed by the operator each day As well we recommend that the operator perform 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 Overall Inspection and Periodic Lubrication and having semi annual Routine Maintenance Inspections performed should ensure years of safe trouble free operations The operator s first visit to an Authorized Service Center should occur once the liftgate has been in operation for 30 days The importance of this initial inspection is to make sure that everything is working prop
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5. ather Over filled reservoir Air in system Drain to proper volume Raise and lower the platform several times refill if necessary Platform will not open or close or does so slowly Hydraulic system fault Orfice in fitting on open close cylinder is plugged Defective power unit Ground Fault 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 battery minimum 4 battery cable Check the ground from the chassis to the motor minimum 4 battery cable 20 gres a a lt x 2 a CONNECTOR IN POWER UNIT BOX 1 gt 5 gii iue ali ALE Qt Fog A pu 5 1 325 Eli 5 eal OSA li aw tu 1S EE ITEM a ie 1 1 1 a 1 AZx E Pe H ul aro o o 2 a gt A 25 c ZB gt g 521 gt 185 02 5 a gt A gt a LJ aws ut Y Gov NM
6. c oil thickened due to low temperature Check Master Disconnect is ON e Check that Circuit Breaker has not been tripped Check for shorts ground faults or open circuits power lines connected to the ground or a broken cable or connection In below freezing temperatures check for frozen water accumulation in 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 if non functional Check function Replace if non functional Check for and remedy any damage or obstruction in sliders track or path of travel of platform Change to lower viscosity hydraulic oil 15 ILD Series Maintenance amp Service Manual 2 TROUBLE SHOOTING Problem Possible Cause Remedy Liftgate will not raise or raises slowly loaded Reduced hydraulic oil delivery to the cylinder Ground Fault Liftgate overloaded Pump worn Pressure relief valve out of adjustment 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 Chec
7. erly during this break in period Once this is complete we recommend that the operator return semi annually to his or her Authorized Service Center for performance of the Routine Maintenance Inspection ILD Series Maintenance amp Service Manual 1 2 Daily Overall Inspection Run liftgate through its entire cycle daily Check for any unusual noises coming from the liftgate or related items such as the power unit 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 ILD Series Maintenance amp Service Manual STEP 3 Check that all warning decals are in place and legible Any missing or damaged decals need replacement immediately 1 Operating Instructions 4 Urgent Warning 2 Warning Keep Clear 5 Warning Liftgate Can Crush 3 Warning Maximum Load Capacity You may obtain free replacement decals See page 17 for detailed description 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 these steps have been completed daily You will find a sample of this chart on the page that follows Contact your employer to receive a copy to keep in your glove compartment ILD Series Maintenance amp Service Manual 1 3 Per
8. iodic Lubrication Lubrication with lightweight machine oil should be performed at least monthly 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 Duty Medium Duty Heavy Duty 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 platform 2 Lowering rated load and lifting 1 2 rated load 3 Lowering rated load and lifting 11 ILD Series Maintenance amp Service Manual LUBRICATION DIAGRAM Lubricate only the areas shown on the diagram below Lubrication of any other areas will shorten the life of the area lubricated Oil Wear Pads Upper Back and Upper Front both sides Oil Wear Pads Lower Back both sides Grease Platform Folding Pin both sides Grease Platform Hinge Pins both sides 12 ILD Series Maintenance amp Service Manual 2 TROUBLE SHOOTING Problem Possible Cause Remedy Liftgate will not raise or raises 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 Hydrauli
9. k the ground from the chassis to the motor minimum 4 battery cable Decrease load Have pump serviced or replace Adjust Liftgate will not raise to full height Insufficient oil in reservoir Air in hydraulic system Mechanical damage or obstruction Fill with hydraulic oil Raise and lower the liftgate several times and then fill the reservoir with hydraulic oil Check for and remedy any damage or obstruction in sliders track or path of travel of platform 16 ILD Series Maintenance amp Service Manual 2 TROUBLE SHOOTING Problem Possible Cause Remedy Liftgate will not descend or does so slowly Motor not running Little or no hydraulic oil in the reservoir No oil supply to cylinder Defective lift cylinder Hydraulic locking valve on power unit malfunctioning Mechanical damage or obstruction Hydraulic oil thickened due to low temperature Check Master Disconnect is ON e Check that Circuit Breaker has not been tripped Check for shorts ground faults or open circuits power lines connected to the ground or a broken cable or connection In below freezing temperatures check for frozen water accumulation in the motor housing Check motor solenoid Replace if non functional Check control switch Replace if non functional Fill with cor
10. l short circuit Check for electrical short circuit 18 ILD Series Maintenance amp Service Manual 2 TROUBLE SHOOTING Problem Possible Cause Remedy Liftgate descends unevenly Defective flow control Replace valve on passenger side cylinder Defective lift cylinder Replace Liftgate vibrates up and down while lifting Mechanical damage or obstruction Defective lift cylinder Air in system Tank breather is plugged Low pressure feed to pump is restricted Check for and remedy any damage or obstruction in sliders track or path of travel of platform e 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 Excessive battery discharge Alternator generator not working properly Frequent use with insufficient charging time Defective battery Defective pump motor 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 19 ILD Series Maintenance amp Service Manual 2 TROUBLE SHOOTING Problem Possible Cause Remedy Overflowing through reservoir bre
11. rect hydraulic fluid Check for any broken or blocked hoses valves or filters Check function Replace if non functional Check function Replace if non functional Check for and remedy any damage or obstruction in sliders track or path of travel of platform Change to lower viscosity hydraulic oil 17 ILD Series Maintenance amp Service Manual 2 TROUBLE SHOOTING Problem Possible Cause Remedy Liftgate will not descend or Hydrauilic locking Check for poor electrical does so slowly cont valve stuck connections Reduced hydraulic oil Check voltage supply to delivery to the cylinder motor Minimum should be 10 5 volts under load If voltage is too low increase the power supply Ground Fault Check the ground from the chassis to the battery minimum 4 battery cable Check solenoid for proper operation Clean or replace control valve Liftgate creeps down while Leaks in the Check all hoses the platform is in the hydraulic system connections and control unfolded position valves replace or service any faulty parts Worn lift cylinder s Check cylinder packing Replace if necessary Check cylinder for scoring Replace if necessary Hydraulic locking Clean or replace on power unit defective Check plunger assembly for proper adjustment Check for short circuit at valve pin Electrica
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