Powermate LiftGate LG-3 User manual

PN 018900 Rev.E1
PN 389570 Rev.E1
Eng. 06/ 01/ 17
T20-080.08

Section 1 - General
Warning Page………………………………………….
PowerMate LiftGate Description……………………..
Delivery and Warranty Registration………………….
Section 2 - Safety
Hazard Graphical Symbols…………………………...
LiftGate Mandatory Decals…………………………...
Mandatory Safety Decal Placement…………………
Safety Precautions…………………………………….
Section 3 - Instructions
LiftGate Operating Instruction………………………..
Loading Instruction for 250 Lb. LiftGate…………….
Loading Instruction for 500 Lb. LiftGate…………….
Installation Dimensional Requirements……………..
Installation Kit………………………………………….
Additional Items and Tools……………………………
Determining Installation Location…………………….
Base Hole Locations…………………………………..
Installing the LiftGate Unit…………………………….
Running the Wires……………………………………..
Section 4 - LG-Series PowerMate Components
Replacement Component Drawing………………….
Replacement Component List………………………..
Section 5 - Maintenance
Maintaining 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 - Accessory Installations
Cradle Attachment Installation……………………….
Section 8 - Accessories
LG-3 LiftGate Features………………………………..
LG-6 LiftGate Features………………………………..
Warranty………………………………………………..
Declaration of Conformity…………………………….
Daily Maintenance Schedule…………………………
1.01
1.02
1.02
2.01
2.02
2.04
2.05
3.01
3.02
3.03
3.04
3.05
3.06
3.07
3.08
3.09
3.10
4.01
4.02
5.01
5.02
5.03
5.04
5.05
5.06
5.07
5.08
5.09
5.10
6.01
7.01
8.01
8.02
8.03
8.04
8.05
PowerMate
®
LiftGate™ Installation & Operation Manual
TABLE OF CONTENTS
PN 018020 Rev. E
Eng. 11/ 10/ 15
i

W
ARNING
ATTENTION!
The photographs, diagrams and illustrations in his
manual are of the LG-6 Right-hand unit installation in
a box truck. Use this manual as a guideline when
installing Left-hand units and/or other LG-Series units
in alternative locations in other vehicle types.
Failure to 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
1-800-697-6283
PowerMate
®
LiftGate™ Installation & Operation Manual
PN 018100 Rev.D2
Eng. 01/ 10/ 13
1.01

Manufactured By:
L P INTERNATIONAL INC.
P.O. Box 696, 151 Savannah Oaks Drive
Brantford, Ontario, Canada N3T 5P9
TEL: [phone] FAX: [phone]
1-800-697-6283

PowerMate
®
LiftGate™
DELIVERY AND WARRANTY REGISTRATION
In choosing to buy a PowerMate
®
, you will find that it will help your business in more
ways than you can imagine. Not only is it a revenue generator, PowerMate®is also a
labour saver and a great promotional tool to help you expand your business in the
commercial and industrial markets.
The PowerMate®LiftGate™ provides a safe and easy way for moving and delivering
heavy and awkward loads in and out of your vehicle at the push of a button.
We at L P INTERNATIONAL INC. look forward to continuing our mission to help you
realize your full profit potential of having a PowerMate®LiftGate™ in your Profit
Center.
For more information 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.
Registering your unit for the Warranty can be done online at www.powermate.info.
Click on Service, fill in the required fields under Warranty and click Send Now.
When ordering parts, or requesting information or service on the unit, please refer
to the model and serial number. The model number can be found on the data
decal on the top of the control box. The serial number can be found stamped to
the top corner of the aluminum outer frame.
PowerMate
®
LiftGate™ Installation & Operation Manual
WARNING The use of this equipment with any options other than
those specified in this manual may create a hazard.
PN 018910
Rev.D2
Eng. 01/ 10/ 13
1.02

The PowerMate
®
products use graphical symbols, safety colours, and signal words
throughout the Operators Manual and on the units themselves. Operators using the
PowerMate®must familiarize themselves with these symbols.
NOTICE: The signal word to address practices not
related to personal injury.
CAUTION: Indicates a potentially hazardous situation
which, if not avoided, may result in minor
or moderate injury.
WARNING: Indicates a potentially hazardous situation
which, if not avoided, could result in death
or serious injury.
DANGER: Indicates an imminently hazardous situation
which, if not avoided, 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 maintained to provide legible
safety information. Clean the labels with soap and water. Do not use solvent-based
cleaners because they may damage the labels. Replace damaged or missing labels.
Replacement labels may be purchased from L P International Inc. Customer Service
Phone number 1-800-697-Mate.
PowerMate
®
LiftGate™ Installation & Operation Manual
2.01 PN 018090 Rev.D2
Eng. 01/ 10/ 13

PowerMate
®
LiftGate™ Installation & Operation Manual
DANGERS, WARNINGS, AND CAUTIONS
The following decals 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

PowerMate
®
LiftGate™ Installation & Operation Manual
A
DDITIONAL MANDATORY DECALS
The following decals are mandatory. Refer to the Location of Mandatory Labels Drawing
for placement. Replacement decals are available from LP International Inc.
230(104)
210(95)
190(86)
170(77)
250(113)
250(113)Max.
400(181)
300(136)
200(91)
100(45)
500(227)
500(227)Max.
TOEPLATEFACE
LOAD CENTER OF GRAVITY
4" 8" 12" 24"
18"
LOAD
lbs.(kgs.)
WARNING
LOAD MUST BE SECURED TO THE UNIT WITH
THE RATCHET STRAP PROVIDED.
POWERMATE
LIFT GATE 250Lb.(113Kg.) SERIES
16"
PN 082600
PN 082860 - 2 Required
PN 082610
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
TOEPLATEFACE
LOAD CENTER OF GRAVITY
4" 8" 12" 16" 18" 24"
LOAD
lbs.(kgs.)
LIFT GATE 500Lb.(227Kg.) SERIES
POWERMATE
WARNING
LOAD MUST BE SECURED TO THE UNIT WITH
THE RATCHET STRAP PROVIDED.
PN 083600
PN 083610
PN 08362X
PN 083860 - 2 Required
POWERMATE LIFT GATE SERIES
Model No. LG−"X"
Load Capacity: 500lbs./227kgs.
Unit Useable Stroke: 40in./1.02m
Unit Weight: 230 lbs./104kgs.
Voltage: 12vdc Amperage: 30A Max.
Made in CANADA
Note: "X" will be Unit Size
"3" - LG-3 Unit
"6" - LG-6 Unit
2.03

PowerMate
®
LiftGate™ Installation & Operation Manual
LOCATION OF MANDATORY
LABELS FOR 250Lb. AND
500Lb. LIFTGATE UNITS
NOTE: Indicated Decals are intended to create awareness in
operators, owners, and maintenance personnel, of the
potential safety hazards and operational limits. Insure
that these decals are in place. Replacements are
available from L P International Inc.
PARTS LIST
DESCRIPTIONPART No.QTYITEM
DANGER DECAL - CRUSH HAZARD FOOT05702011
DECAL - MOVING PARTS
08265012
DECAL - WARNING MOVING PARTS FUSE08288013
WARNING DECAL - KEEP OFF
05705014
DECAL - WARNING AUTHORIZED PERSONNEL0570101
5
DECAL - LOAD CAPACITY 250Lb.
DECAL - LOAD CAPACITY 500Lb.
082860
083860
26
DECAL - SAFETY INSTRUCTION 250Lb.
DECAL - SAFETY INSTRUCTION 500Lb.
082610
083610
1
7
DECAL - LOADING CHART 250Lb. SERIES
DECAL - LOADING CHART 500Lb. SERIES
082600
083600
18
DECAL - LG SPECIFICATIONS 250Lb.
DECAL - LG SPECIFICATIONS 500Lb.
08262X
08362X
19
DECAL - INSTALLATION/OPERATING MANUAL082630110
DECAL - LOAD UP/DOWN LG-SERIES
082830111
PN 018030 Rev.D2
Eng. 01/ 10/ 13
Note: "X" will
be Unit Size
6
7
3
9
11
10
5
1
4
6
8
2
2.04

PowerMate
®
LiftGate™ Installation & Operation Manual
WARNING:Read and understand all instructions. Follow the safety rules listed below
as well as the other basic safety precautions. Failure to do so may result
in serious injury.
WORK ARE
A
CHECK YOUR WORK AREA. Inspect your work are for obstacles such as holes,
debris or rough spots. Look for areas not able to support the load, such as access
or drain covers or soft ground. Watch out for liquid spills or slippery surfaces. Be
on the alert for anything that might cause you to lose your balance, control or
concentration. Insure that the vehicle is level. The LiftGate™ unit should not be
activated if the vehicle is on any inclination.
PLAN YOUR WORK. Arrange your work to avoid unnecessary steps or effort.
Position your vehicle for proper clearance from roadside curbs and obstacles.
Insure that the Load Chart is considered when engaging the load to be
transferred. Do not overload the PowerMate.
KEEP YOUR WORK AREA CLEAR. All visitors should be kept away from the
work area.
PERSONAL SAFET
Y
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 injured.
Keep both hands positioned on unit at all times. Never play games. Do not ride on
the unit. Do not attempt to use the equipment as a jack.
MAINTAIN THE EQUIPMENT REGULARLY
DO NOT operate equipment that is known to be damaged or malfunctioning. Never
remove or override any mechanical or electrical safety devices. Poorly maintained
equipment jeopardizes the safety of the operator and all other personnel. Remember
safety is your responsibility. Complete a daily inspection procedure. Have the
equipment thoroughly checked by a competent service person at least once a year.
SECURE FOR TRANSPORT
When the equipment is not in use, ensure the LiftGate™ and the load are fully secure
before moving the vehicle.
PN 018110 Rev.D2
Eng. 01/ 10/ 13
SAFETY PRECAUTIONS
2.05

DETAIL A
1. Refer to the Loading Chart, in this Manual or on the face of the LiftGate Unit, to
determine if the load to be lifted will fit in the load capacity envelope of the Unit.
2. The Rocker Switch controls the up/down operation of the unit. Depressing the
top of the switch will raise the toeplate and depressing the bottom of the switch
will lower the toeplate. Raise the toeplate off the surface and dis-engage the
Lock Pin, to allow positioning of the Unit. Manuever the toeplate to the load and
lower the toeplate to the surface. Place load on the toeplate and secure the
load to the Unit using the strap provided.
3. Raise the load to the desired height. The actuator will make a ratcheting sound
when the top stroke limit is reached.
4. Swing the 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 actuator stops(automatic), and
depress the Emergency Stop/Battery Disconnect Switch.
WARNING! The vehicle must be parked on a level surface prior to operating the
LiftGate Unit. Safety shoes must be worn! Read the instructions completely
before operating the unit. DO NOT exceed Max. Capacity Limit.
PowerMate
®
LiftGate™ Installation & Operation Manual
OPERATING INSTRUCTIONS
A
PN 018330 Rev.D2
Eng. 01/ 10/ 13
Lock Pin
Main Swing Arm
Top Handle
Bottom Handle
Actuator
Control Box
Fuse Holder
with 30A Fuse
Emergency Stop/
Battery Disconnect
Switch
Rocker Switch
3.01

PowerMate
®
LiftGate™ Installation & Operation Manual
INSTRUCTIONS:
The above Loading Chart, shown with an example cylinder load, indicates the maximum load
that can be liftedby the LiftGate Unit at a specific center of gravity. The center of gravity is
measured as the distance from face of the Toeplate to the balance point of the load. 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.
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)
210(95)
190(86)
170(77)
250(113)
250(113)Max.
TOEPLATEFACE
LOAD CENTER OF GRAVITY
4" 8" 12" 24"
18"
LOAD
lbs.(kgs.)
POWERMATE
LIFT GATE 250Lb.(113Kg.) SERIES
16"
PN 018310 Rev.D2
Eng. 01 / 10/ 13
3.02

PowerMate
®
LiftGate™ Installation & Operation Manual
LOAD MUST BE SECURED TO THE UNIT WITH
THE RATCHET STRAP PROVIDED.
The above Loading Chart, shown with an example cylinder load, indicates the maximum load
that can be liftedby the LiftGate Unit at a specific center of gravity. The center of gravity is
measured as the distance from face of the Toeplate to the balance point of the load. 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)Max. 500(227)
400(181)
300(136)
200(91)
100(45)
TOEPLATEFACE
LOAD CENTER OF GRAVITY
4" 8" 12" 24"
18"
LOAD
lbs.(kgs.)
POWERMATE
LIFT GATE 500Lb.(227kg.) SERIES
16"
PN 018320 Rev.D2
Eng. 01/ 10/ 13
3.03

PowerMate
®
LiftGate™ Installation & Operation Manual
INSTALLATION DIMENSIONAL 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

PowerMate
®
LiftGate™ Installation & Operation Manual
INSTALLATION KIT
Your installation package should include the following:
1 PowerMate® LiftGate™ Unit complete with pre-drilled Base
1 Wiring Kit which includes the following:
1 Maxi-Fuse Fuse Holder
2 40A Fuses (1 is a spare)
1 Fuse Holder Cover
1 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
Maxi-Fuse Fuse Holder
11"Cable Tie
6Ga. Cable Splice
Crimped with loose
Heat Shrink Tube
3.05

PowerMate
®
LiftGate™ Installation & Operation Manual
ADDITIONAL ITEMS & TOOLS
NOTE:
Some adjustments to the Unit's Base Plate may need to be made in order to fit
the Unit around some areas of the vehicle (wheel wells, etc.) A cutting torch
may be required to reshape the Unit's Base Plate.
The installer will need to provide following tools and materials to proceed 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 of vehicle floor and vehicle floo
r
reinforcement. Therefore, bolt length can only be determined at time of installment.
PN 018420 Rev.D2
Eng. 01/ 10/ 13
3.06

INSTALLING YOUR PowerMate® LiftGate

STEP 1: Determining the location of unit installation.
A. Although you will want the Unit placed close to the rear doors and side of the
vehicle, you will need 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

PowerMate
®
LiftGate™ Installation & Operation Manual
B. Position the Unit in the vehicle and mark the outline of the Base Plate on the floor.
Using a transfer punch and the Unit Base as a template, mark the bolt hole
locations on the vehicle floor. Move the Unit out of the way. Using the dimensions
provided in the sketch below, mark the center point of the large hole.
CAUTION!!
Before any holes are made in the vehicle floor, ensure the following: The large
hole for the wiring must not damage the vehicle's supporting structure. Check the
underbody of the vehicle 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"holes through vehicle
floor as required. Be cautious of
what may be on the bottom side.
Utilize as many hole positions as
possible. Additional holes may be
drilled through the Base Plate if
necessary.
This area is removed on the
LG-3 Lefthand Base Plates.
This area is removed on the
LG-3 Righthand Base Plates.
.750
3.500
PN 018440 Rev.D2
Eng. 01/ 10/ 13
3.08

INSTALLING YOUR PowerMate® LiftGate 
STEP 2: Installing the Unit
C. Proceed to drill the marked large hole and 13/32"
holes into the floor of the vehicle. Use as many
bolt holes in the Base as possible.
NOTE:
In some instances it may not be possible to utilize
all the bolt holes due to the structuring underneath
the
vehicle floor. In these cases, additional holes can
be added.
CAUTION!!
Be sure to not drill into anything 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 Steel Flatbar,
Angle, and/or C-Channel.
NOTE:
Reinforcing steel will need to be measured, cut to
size and drilled with 13/32" holes.
PowerMate
®
LiftGate™ Installation & Operation Manual
PN 018450 Rev.D2
Eng. 01/ 10/ 13
3.09

INSTALLING YOUR PowerMate® LiftGate

F. Secure the Base to the floor and the reinforcing steel with
3/8"-16NC Bolts, Washers and Lock Nuts.
STEP 3: Running the wires
CAUTION!!
The best and easiest way to route the wire from the Unit to the
vehicle battery is to follow the path from the rear lights. If this is not
feasible you must avoid the following:
I. Any heat sources. EG. Exhaust system.
II. Any pinch points. 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 protective wire loom for the entire length of wire
installation including up through the floor into the Base
Assembly.
PowerMate
®
LiftGate™ Installation & Operation Manual
PN 018460 Rev.D2
Eng. 01/ 10/ 13
3.10

INSTALLING YOUR PowerMate® LiftGate

K. Route the 6Ga. wire to the vehicle battery, securing
wire to vehicle frame as required.
L. Slip a piece of Heat 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