Powermate LiftGate LG-3 Installation & Operation Manual Download Page 27 | Manualshive

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DETAIL A

PowerMate

®

LiftGate™

Installation & Operation Manual

LIMIT SWITCH ASSEMBLY/ADJUSTMENT

A

3/32"Approx.

Limit Switch Cover

Limit Switch

Wire Loom

Main Frame Tube

Wire Loom

PN 018880 Rev.D2

Eng. 01/ 10/ 13

Wire Loom

10-32NF Screws(4)

Switch Cover

Screws(2)

Strain Relief

Base Post

Urethane Post Cap

10-32NF Lock Nuts

1/2"Cable Clip

1/4-20NC Set Screws

Mounting Ring/Bracket

5.05

Urethane Post Cap

Base Post

Mounting Ring/Bracket

Limit Switch Roller

Limit Switch Screw(2)

Strain Relief

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Summary of Contents for LiftGate LG-3

Page 1: ...PN 018900 Rev E1 PN 389570 Rev E1 Eng 06 01 17 T20 080 08 ...

Page 2: ...ning The PowerMate LiftGate Actuator Removal Installation Instruction Actuator Removal Installation Instruction Drawing Limit Switch Assembly Adjustment Instruction Limit Switch Assembly Adjustment Drawing Roller Replacement Lefthand Strapbar Assembly Righthand Strapbar Assembly LG Series Wiring Diagram Actuator Manual Retraction Section 6 Specifications PowerMate LiftGate Specifications Section 7...

Page 3: ... obey the Instructions and Safety rules in this manual could result in death or serious injury Read the Operating Manual completely Only competent trained operators may use this equipment Training is essential to understanding all the features and capabilities of your PowerMate and ensure good safe work practices Training courses are available through L P INTERNATIONAL INC please call 1 800 697 62...

Page 4: ...ion on the complete PowerMate product line please call toll free 1 800 697 6283 Upon receipt of your LiftGate unit examine the unit to determine if it has been damaged in transit Examine the unit for mishandling paying particular attention to the control box and switches the limit switch assembly and the exposed wire looms If required make note of any deficiencies on the Delivery Acceptance Form R...

Page 5: ...oided will result in death or serious injury Safety Alert Symbol This symbol indicates a potential personal injury hazard Safety information following this symbol must be followed to avoid possible injury or death HAZARD GRAPHICAL SYMBOLS SAFETY LABEL MAINTENANCE Safety of the operator and surrounding environment must be considered at all times To that end safety labelling on the PowerMate must be...

Page 6: ...ecals are mandatory Refer to the Location of Mandatory Labels Drawing for placement Replacement decals are available from LP International Inc PN 057020 1 Required PN 082650 1 Required PN 057050 1 Required PN 082880 1 Required PN 057010 1 Required PN 018040 Rev D2 Sheet 1 of 2 Eng 01 10 13 2 02 ...

Page 7: ...0 Load Capacity 250lbs 113kgs Unit Useable Stroke 40in 1 02m Unit Weight 230 lbs 104kgs Voltage 12vdc Amperage 30A Max Made in CANADA POWERMATE LIFT GATE SERIES Model No LG X PN 08262X PN 082630 PN 082830 PN 018040 Rev D2 Sheet 2 of 2 Eng 01 10 13 Note X will be Unit Size 3 LG 3 Unit 6 LG 6 Unit TOEPLATE FACE LOAD CENTER OF GRAVITY 4 8 12 16 18 24 LOAD lbs kgs LIFT GATE 500Lb 227Kg SERIES POWERMAT...

Page 8: ... 1 DECAL MOVING PARTS 082650 1 2 DECAL WARNING MOVING PARTS FUSE 082880 1 3 WARNING DECAL KEEP OFF 057050 1 4 DECAL WARNING AUTHORIZED PERSONNEL 057010 1 5 DECAL LOAD CAPACITY 250Lb DECAL LOAD CAPACITY 500Lb 082860 083860 2 6 DECAL SAFETY INSTRUCTION 250Lb DECAL SAFETY INSTRUCTION 500Lb 082610 083610 1 7 DECAL LOADING CHART 250Lb SERIES DECAL LOADING CHART 500Lb SERIES 082600 083600 1 8 DECAL LG S...

Page 9: ...AR All visitors should be kept away from the work area PERSONAL SAFETY STAY ALERT Always focus your attention in the direction of travel Always maintain proper footing and balance Constantly check for clearance above below and on all sides When loading onto or off of a vehicle be prepared for movement in the vehicle suspension system USE COMMON SENSE Do not operate equipment when you are tired or ...

Page 10: ...he load to required position using the Unit Handles Use the Lock Pin whenever possible 5 Lower the load down to the desired surface vehicle floor or the ground The down stroke will end automaticly when the toeplate makes contact with any surface Remove the load 6 When the operation is complete park the Unit folded in the vehicle Engage the lock pin lower the toeplate to the floor until the actuato...

Page 11: ...gravity distance out from the face of the Toeplate Locate on the chart the Weight Center of Gravity location for the load The load must not exceed the weight limit for the given center of gravity distance POWERMATE 250Lb LIFTGATE LOAD CHART LOAD MUST BE SECURED TO THE UNIT WITH THE RATCHET STRAP PROVIDED WARNING NOTE This is a copy of the Load Chart on the Outer Frame of the Lift Gate Unit 230 104...

Page 12: ... Estimate the weight of the load and the center of gravity distance out from the face of the Toeplate Locate on the chart the Weight Center of Gravity location for the load The load must not exceed the weight limit for the given center of gravity distance NOTE This is a copy of the Load Chart on the Outer Frame of the Lift Gate Unit WARNING INSTRUCTIONS POWERMATE 500Lb LIFTGATE LOAD CHART 500 227 ...

Page 13: ...AL REQUIREMENTS LiftGate Model No Minimum Door Opening Maximum Height of Base above ground LG 3 LG 5 LG 6 47 3 4 1212mm 28 711mm 59 1498mm 36 915mm 63 1600mm 40 1016mm Minimum Door Opening 25 3 4 24 3 4 Maximum height of base above ground PN 018400 Rev D2 Eng 01 10 13 3 04 ...

Page 14: ... Cable Splice 6Ga spare 1 Copper Lug 6Ga spare 1 Approx 33 of 6Ga Electrical Wire 20 11 Cable Ties 1 30A AGC Fuse spare 2 Heat Shrink Tubes 3 8 x 2 1 Positioning Template Drawing 1 Lock Pin Plug 6Ga Copper Lug Crimped and Heat Shrunk PN 018410 Rev D2 Eng 01 10 13 Lock Pin Lug Approx 33 of 6Ga Cable with attached Cable Splice and loose Heat Shrink Tube 40A Fuse Fuse Holder Cover Spare 30A AGC Fuse ...

Page 15: ...ceed with installation Drill with 13 32 Metal Drill Bit 1 to 2 Metal Hole Saw Wire Cutter Crimping Pliers 9 16 Wrench 9 16 Socket Ratchet 3 8 16NC Bolts of suitable length Wire Loom for wire protection Steel Flat Bar Angle and or C Channel for vehicle floor reinforcement Screw or Bolt Nut combination to secure Ground Lug Terminal to vehicle frame The length of the Bolts are dependant on thickness ...

Page 16: ... to ensure the proper allowances I Make sure there is enough room to close the rear doors II The Base Pole must be far enough away from the vehicle wall to clear the doorway when swinging out and allow you to easily access the Locking Pin Below Example LG 6 LiftGate placement in rear location of a truck box PowerMate LiftGate Installation Operation Manual PN 018430 Rev D2 Eng 01 10 13 3 07 ...

Page 17: ...le to ensure the hole locations will not interfere with brake or fuel lines fuel tank wiring or any other critical areas of the vehicle If the area is not free of obstacles re position the Unit and repeat this step POWERMATE LIFTGATE BASE HOLE LOCATIONS Make 1 to 2 hole at this location for wiring to pass through floor of vehicle 12 000 15 500 20 000 6 000 750 3 000 2 875 750 4 625 438 Drill 13 32...

Page 18: ...hing vital under the floor D Reposition the PowerMate LiftGate Unit over the marked outline lining up the large hole with the Main Post Tip the Unit back to fish out the two wires hidden in the Main Post Direct the wires through the large hole in the floor CAUTION Care must be taken not to damage the wires E The installer is required to reinforce the Unit under the floor below the Base Plate with ...

Page 19: ...oints EG Suspension system III Any areas that may cause chaffing to occur on the wiring G The BLACK wire that exits the Base Assembly and is fed through the floor must be fastened to a suitable Ground on the vehicle frame H Slip a piece of Heat Shrink Tube over the RED wire I Connect the RED wire to the 6Ga wire using the 6Ga Cable Splice and shrink the tubing over the connection J Provide a prote...

Page 20: ...at Shrink Tube over the 6Ga wire Join wire to Fuse Holder with 6Ga Cable Splice and shrink tubing over the connection M Attach Cable Lug to POSITIVE post of the battery N Insert the 40A Fuse into the Fuse Holder and attach the Fuse Holder Cover O Test the Unit PowerMate LiftGate Installation Operation Manual PN 018470 Rev D2 Eng 01 10 13 3 11 ...

Page 21: ... 2 5 3 5 7 5 6 5 5 5 4 24 5 1 7 8 10 4 2 4 3 4 4 4 5 6 31 32 17 1 17 5 17 4 17 3 17 2 13 15 16 18 11 13 22 11 POWERMATE LG SERIES LIFTGATE REPLACEMENT COMPONENT DRAWING PN 018500 Rev D2 Sheet 1 of 2 Eng 01 10 13 4 9 5 6 6 5 10 5 9 5 8 5 8 5 11 22 4 10 29 30 25 26 6 26 6 26 4 26 3 26 2 28 4 01 ...

Page 22: ...E ASSEMBLY LG 8 2 050750 BOLT 1 4 20NC x 3 4 HEX HD ZINC PARTS LIST ITEM QTY PART No DESCRIPTION 9 1 385210 HINGE INNER TUBE LG 6 PF 10 2 385285 ROLLER GUARD LG PF 11 2 050574 SCREW THRD CUT 8 32 x 1 4 12 1 385376B SCREW COVER LG 6 PF 13 6 050576 SCREW THRD CUT 10 24 x 1 2 14 2 050725 BOLT 1 2 x 1 1 2 Lg SHOULDER 15 4 050140 WASHER THRUST STEEL 1 2 090 16 2 050636 NUT 3 8 16NC FLANGE ZINC 17 1 1 1...

Page 23: ... excessive movement between Inner and Outer Aluminum Frames 6 Apply silicone lubricant EG LPS to Top Urethane Rollers Wipe off excess oil 7 Check that Toe Plate is secure and not bent 8 If Cylinder Attachment is installed Check operation of Ratchet Tie Down Unit and Strap Check to see if Eye Bolt for Strap is bent indicating over tightening Check to see if Strap is cut or frayed If so replace imme...

Page 24: ...Inner Frame assembly passing the Actuator motor through the cutout in the Inner Frame Lift the Actuator up and out of the Inner Frame Assembly NOTE If the Actuator is going to be out of the unit for any length of time the Toeplate Outer Frame Assembly may be lifted up manually and the unit may be swung back into the vehicle to its storage position STEP 1 If not in already in position manually lift...

Page 25: ... Actuator Guard Outer Frame Inner Frame Swing Frame Toeplate Typ 2 Typ 2 PN 018860 Rev D2 Eng 01 10 13 10 24NC Screws 1 2 Shoulder Bolt 1 5 Lg Top Clevis Mount 3 8 16NC Nut 1 2 Washer 090 Thick Inner Frame Actuator Toeplate Outer Frame Bottom Clevis Mounts 1 2 Shoulder Bolt 1 5 Lg 3 8 16NC Nut 1 2 Washer 090 Thick 5 03 ...

Page 26: ...s Do not tighten Feed the power wires and blue control wires through the urethane ring in the top of the Post Fish the two power wires out of the Base Post from beneath the vehicle Re splice the power wire red together Re attach the ground lug to the vehicle frame Re install fuse at the battery LIMIT SWITCH INSTALLATION Mount the Limit Switch on the Mounting Bracket using the four 10 32NF Screws D...

Page 27: ...ire Loom Main Frame Tube Wire Loom PN 018880 Rev D2 Eng 01 10 13 Wire Loom 10 32NF Screws 4 Switch Cover Screws 2 Strain Relief Base Post Urethane Post Cap 10 32NF Lock Nuts 1 2 Cable Clip 1 4 20NC Set Screws Mounting Ring Bracket 5 05 Urethane Post Cap Base Post Mounting Ring Bracket Limit Switch Roller Limit Switch Screw 2 Strain Relief ...

Page 28: ...ition STEP 5 Remove the old Rollers and wipe the Roller Axles clean Remove any nicks or burrs on the axles STEP 6 Apply a light machine lubricant to the four Roller Axles and install the new Rollers Wipe off excess lubricant STEP 7 Supporting the Outer Frame remove the support underneath the Toeplate Lower the Outer Frame to re engage the Rollers in the Inner and Outer Frames Continue to lower unt...

Page 29: ...1 4 SCREW HEXSOC SET 5 16 18 x 5 16 050990 1 5 STRAPBAR CONNECTOR LS 110020D 2 6 NUT 1 4 20 RING LOCK ZINC 050610 6 7 PLATE WASHER 1 4 ZINC 050070 3 8 SCREW PAN HD SLOT 1 4 20x1 1 4 050580 2 9 SCREW 1 4 20NC THUMB 050583 2 10 BOLT 1 4 20 x 7 8 CARRIAGE ZINC 050740 1 11 FELT STRAP BAR 1 4 x 2 x 19 180135 1 12 NOTE Strap not shown for clarity 1 11 12 3 5 2 7 10 6 4 9 8 7 PN 018640 Rev D2 Sheet 1 of ...

Page 30: ...SCREW HEXSOC SET 5 16 18 x 5 16 050990 1 5 STRAPBAR CONNECTOR LS 110020D 2 6 NUT 1 4 20 RING LOCK ZINC 050610 6 7 PLATE WASHER 1 4 ZINC 050070 3 8 SCREW PAN HD SLOT 1 4 20x1 1 4 050580 2 9 SCREW 1 4 20NC THUMB 050583 2 10 BOLT 1 4 20 x 7 8 CARRIAGE ZINC 050740 1 11 FELT STRAP BAR 1 4 x 2 x 19 180135 1 12 NOTE Strap not shown for clarity 3 5 2 11 12 1 7 8 9 4 6 7 7 10 10 5 08 PN 018640 Rev D2 Sheet...

Page 31: ...ration Manual LG SERIES WIRING DIAGRAM LIMIT SWITCH Normally Open 12V MOTOR FUSE HOLDER with 30A FUSE RELAY Normally Closed HEAVY DUTY SWITCH ROCKER SWITCH FUSE HOLDER with 40A FUSE 12V VEHICLE BATTERY PN 018690 Rev D2 Eng 01 10 13 5 09 ...

Page 32: ...n extended position the Actuator can be retracted using the 5 16 Allen Key provided Before proceeding insure the Battery Disconnect Switch is in the disable pushed in position Remove the Plastic Plug from the top of the Actuator Gearbox Housing press fit insert the 5 16 Allen Key into the hole and engage the small gear visible through the hole Rotate the Allen Key clockwise until the Actuator is f...

Page 33: ...6 01 PN 081950 Rev D2 Eng 01 10 13 ...

Page 34: ...ttachment as a guide drill a 9 32 hole through the Outer Frame CAREFULL Take care not to hit the Actuator Inner Tube when breaking through Step 3 Insert a 1 4 20NC x 3 4 Bolt from the Cradle side and secure the Attachment with 1 4 20NC Lock Nut Cradle Attachment Lefthand PN 480060 Cradle Attachment Righthand PN 480065 A Righthand unit shown Strap removed for clarity Outer Frame Cradle Attachment 1...

Page 35: ...PN018920 Rev D2 Eng 01 10 13 8 01 ...

Page 36: ...PN 018940 Rev D2 Eng 01 10 13 8 02 ...

Page 37: ...ospheric or chemical influences nor defects due to unskilled operation lack of maintenance and use of unprescribed lubricants Neither do they accept responsibility for normal wear and tear and consequences therefrom Warranty Service is available through your local authorized dealer or distributor Warranty is void if serviced by unauthorized persons Machine Model Serial No Manufactured By L P INTER...

Page 38: ...INTENTIONALLY BLANK ...

Page 39: ...el Serial conforms to the protection requirements of Council directive 2006 42 EC Machinery Directive 2004 108 EC Electromagnetic Compatibility Directive on the approximation of the laws of the Member States relating to machinery directive and electromagnetic compatibility STANDARDS including Annex 1 of 2006 42 EC and 4 Lifting NAME L Jeavons TITLE General Manager SIGNATURE S01 007 01 ...

Page 40: ...ndition and operation Make sure the wiring is secure Test the battery disconnect switch for operation Cycle the unit testing for operation direction and smoothness Check that the toeplate is secure and not bent Observe the roller operation in the outer frame rails Oil rollers as required Ensure the operation manual is readily available for reference PowerMate LiftGate Installation Operation Manual...

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