Tail Gate Loader Installation Manual
Contents
1. TRAY WIDTH MARK 8 PUNCH ALL HOLES DRILL ALL HOLES 12 5mm 1 27 551 BACK 0F UTE TRAY 130 155 v y TRAY WIDTH 1635 u 2 ___ Figure 2 Locating the LycoLoader 1 Mark and punch the holes as indicated in Figure 2 above 2 Drill a 12 5mm hole at the marked positions CAUTION The bolt hole should clear all of under tray braces and componentry Position the holes accordingly before drilling Also ensure the area to be drilled is free of under tray componentry such as lights and or wiring etc COMBING RAIL APPLICABLE _ 7 REAR EDGE AF TRAY ENSURE BOLTS WILL CLEAR TRAY BRACES BEFORE DRILLING HOLES POSITION HOLES TO SUIT 55 75 pss DASHED LINE DENOTES Figure 3 Bolt Clearance INSTALLING THE TRAY BRACKETS The tray brackets must sit flat on the tray If the tray has a combing rail around the edge of it a suitable spacer plate must be used See Figure 4 below for further details CUT A SPACER PLATE AS SHOWN THE PLATE SHOULD BE 60mm WIDE SPACER PLATE 150 COMBING RAIL Figure 4 Using Spacer Plate LIGHT TRAYS For light trays e g aluminium timber or light gauge steel extra support in the form of under tray reinforcement needs to be added to ensure the load is spread across the tray For suggestions on tray supports see Appendix 1 NOTE ALTERNA2. Do operate with unstable loads e Do operate with live loads Do operate on uneven ground e Keep hands and feet clear while operating e Ensure towbar is clear of platform e Remove handle before moving vehicle e Stow platform before moving vehicle e Only qualified persons should operate mechanism Do not use external power devices to operate mechanism e Stop winding the handle when the platform is fully raised Product Warranty Lyco Innovations warrant to the owner of each new product sold that for the specified period commencing from the date of purchase that at its discretion Lyco will repair or replace free of charge any product or component found to be defective in materials and or workmanship The standard product warranty period is for 12 months or 1040 hours of operation whichever occurs first Warranty periods different to this are specified on Lyco Innovations sales brochures This warranty shall exclude defects occurring through incorrect or inappropriate storage transport non Lyco design application use or accident wilful damage or as a result of unauthorised or incompetent servicing by other than Lyco staff or authorised persons Notwithstanding any statutory obligations under certain legislation including the Trade Practices Act prevailing in the state or territory the product was sold Lyco accepts no liability for any consequential loss or damage due to product failure or lat
3. Place a 12mm Zinc Plated Washer Item 13 onto a 12mm x 75mm Bolts Item 9 Insert the Bolt thru the Tray Bracket Spacer if required Under Tray Support if required and Tray Repeat for both holes 4 Place a 12mmZinc Plated Washer Item 13 on each bolt followed by a 12mm Nyloc Nut 15 and tighten to a torque of 25 to 30 Nm CAUTION THE TRAY BRACKETS MUST BE SECURELY FIXED TO THE TRAY THE LOAD SHOULD BE SPREAD ACROSS THE TRAY INSTALLING THE TENSION STRAPS 10mm WASHER 10mm WASHER 10mm NYLOC M10 x SOmmL SHORT LINK PLATFORM THIS SIDE LONG LINK Figure 7 Installing the Tension Straps Left Hand Side gt Tighten the nut firm while still allowing the tension strap to move freely Repeat this for both tension straps ensuring that the straps are on the inside of each tray brackets Insert 10 x 50mm 11 thru the short arm of the tension strap Item 41 Place a 10mm zinc plated washer Item 14 on the 10mm bolt Insert the bolt thru the top hole in the left hand tray bracket Item 2 Place a 10mm zinc plated washer Item 14 on the bolt followed by a 10mm nyloc nut Item 16 Tighten the nyloc nut ensuring the tension strap is free to rotate Repeat the procedure on the right hand tray bracket ensuring that the tension strap is placed on the inside of the tray bracket ATTACHING THE TENSION STRAPS Figure 8 Raising
4. the Platform to Attach the Tension Straps Lift the LycoLoader platform by the T Section supporting it until the angle of the slot in the tension strap long arm matches the angle of the platform T Bolt see Figure 8 above Whilst maintaining the angle of the platform slip the Tension Strap over the platform T Bolt see Figure 9 below Repeat the procedure for both Tension Straps Figure 9 Attaching the Tension Straps OPERATION Check the operation of the unit after it is fitted Ensure all 12mm bolts are tightened securely to a torque of 25 to 30 Nm Test the LycoLoader with the Platform unloaded Refer to Operating Manual full operating procedures and safety precautions prior to loading and unloading the LycoLoader including any test loads Insert the Handle Item 8 into the left hand side of the platform assembly until its triangular end engages the triangular recess of the winding mechanism inside the box section Turn the Handle Anti clockwise to lower the platform Release the handle when the platform is half way down The platform should remain in this position Wind the platform fully down and then back up to ensure there is no interference with any part of the vehicle Repeat the test with a load of approximately 50kg to ensure the LycoLoader is functioning correctly Once the test is satisfactorily completed secure the platform in its hinged upright position and ensu
5. TIVE CONFIGURATIONS MAY NEED BE DETERMINED FOR SOME TRAY TYPES lo x 75mm 12mm WASHERS lt lt lemm WASHERS nuts Figure 5 Installing the Tray Bracket on Trays that DON T Require Additional Reinforcement Drill 12 5mm hole along the v groove in each Tray Bracket 2 8 Item 3 75mm or as determined to clear the under tray braces from the back edge Place the Left Hand Tray Bracket above the drilled holes on the left hand side of the ute Place a 12mm Zinc Plated Washer 13 onto a 12mm x 75mm Bolts 9 Insert the Bolt thru the Tray Bracket Spacer if required Under Tray Support if required and Tray Repeat for both holes Place a 12mm Zinc Plated Washer Item 13 on each bolt followed by a 12mm Nyloc Nut 15 and tighten to a torque of 25 to 30 Nm INSTALLING THE MAIN ASSEMBLY 7500 2mn WASHERS ic l2mm WASHERS CD NYLOC NUTS Figure 6 Installing the Main Assembly CAUTION DO NOT LIFT THE PLATFORM ALONE OR WITHOUT THE AID OF A LIFTING DEVICE 1 Lift the Main Platform Item 1 and insert into the Left Hand Tray Bracket NOTE THIS SHOULD NOT BE DONE ALONE OR WITHOUT THE AID OF LIFTING DEVICE 2 Place the Right Hand Tray Bracket Item 2 onto the right hand side of the Main Platform and position on tray 3
6. Tail Gate Loader Installation Manual REVISION 4 IMPORTANT Please read Safety Warnings and Warranty Information Prior to Installing the LycoLoader on your Vehicle y Please Store Manual in Vehicle Glove Box 4 TABLE OF CONTENTS REVISION 2A EEEE E JMPORTANTX au as Sh EAEE a s gaa ais Nome 1 GENERAL SAFETY WARNINGS REGARDING FITMENILI 3 GENERAL SAFETY WARNINGS FOR OPERATION 3 PRODUCT WARRANTY 4 WARRANTY INFORMATION 5 NOTE TO 6 LYCO PARTS AND SERVICE DIVISION 6 PARTS LIS 7 TOOLS REQUIRED FOR INSTALLATION 7 FITTING INSTRUCTION sccsssssssssssssssscssssessessessssessssessessssessessssessessesessessesessessesessessesessessesessesseseesessesees 9 PREPARING THE UTE TRAY Slogausashasayuispyssqqaypaspakkuywqasqaypa
7. arrangement may be required for attachment between the LycoLoader uprights and the tray body s original drop sides The Side Attachment Kit is NOT INCLUDED in the standard LycoLoader Fitting Kit but can be bought separately from your local dealer or Lyco Parts and Service Please quote Part LL SideAttach TOOLS REQUIRED FOR INSTALLATION The following tools are required for installing you LycoLoader onto your vehicle Hammer Electric Drill Centre Punch Tape Measure Ruler 12 5mm or 173 Drill Bit Socket Set including 19mm 18mm 16mm 14mm 13mm Sockets Ring Spanner Set including 19mm 18mm 16mm 14mm Spanners COACH BOLT 12mm 10 RH TRAY BRACKET CITEM 2 k SPACER 19 5 5 a 5 8 x gt 5 a E 5 gt gt 5 8 WASHER 12 Figure 1 LycoLoader Assembly Drawing NUT l2mn NYLDC 17 ee HANDLE 9 LH TENSION STRAP CITEM 4 LH T SECTION FITTING INSTRUCTIONS PREPARING THE UTE TRAY 1 Remove the existing tailgate from the tray and any parts that may interfere during LycoLoader operation 2 Remove the rear tailgate hinge from the tray gt It may be wise to store the tailgate a safe place for reattachment to the vehicle should you wish to remove the LycoLoader e g for resale purposes etc LOCATING THE LYCOLOADER
8. e delivery and limits any liability that it might nevertheless have to a maximum amount being the invoiced price of the product To ensure ongoing warranty cover subsequent owners must notify Healy Group in writing stating the product the serial number and the date of purchase Philip Healy Managing Director Healy Group P L 4 12 Northumberland Rd Caringbah NSW 2229 Ph 02 95255522 Fax 02 92525513 www healygroup com au lyco loader info healygroup com au BUILT BY HEALYGROUP WARRANTY INFORMATION Procedure for Warranty Claims on Healy Group Products 1 All claims for warranty must be authorised by Healy Group prior to any warranty repairs commencing Customers wanting to claim warranty must provide the following details in writing date and proof of purchase or have returned the Guarantee Registration Card the serial and or identification number s of the product and the reason for such claim 2 A unique warranty number will be issued to the customer or an agent of Healy Groups choice This warranty number must be clearly labelled on all product returned for warranty assessment Product received not clearly labelled with the warranty number will be returned direct to the sender 3 If Lyco accepts the warranty claim an Application for Warranty form will be raised authorising warranty repairs The repair time frame will be confirmed at this point For sub contract repairs the Application for Warranty fo
9. m 71 1854mm 73 For tray bodies outside this range a side attachment arrangement may need to be devised An optional fitting kit the LycoLoader Side Attachment Kit is available to suit wider trays between 1854mm 73 and 1905mm 75 It is available from your local dealer or Lyco Parts and Service For more information on side connections for other tray types please refer to Appendix 3 Figure 11 outlines the set up for installing the side connection plates that are included in the standard fitting kit supplied with each LycoLoader Please note that the following items are removed from the tray body s tailgate and tray sides and reused in the side connection Item Description Location A Tailgate plate Rear Tailgate Outer Edge B Side pivot handle Dropside C Tray side angle Dropside D Handle retainer Dropside Table 2 Re used Parts from Tray 1 Remove ltems A B C amp D from the tailgate and tray side 2 Attach to the tray side using the same bolts that were used to hold it to the tailgate making sure the raised latch stop is on the outside of the plate 3 Place one that was used to attach B to the tray side thru 7 thru B and finally thru 6 Also fasten the bottom of B to 6 4 Slide D into 7 5 Insert into B amp D Fasten with spring washer and nut previously removed 6 Attach
10. re the retaining catches on the tray brackets are fully fastened Store the LycoLoader handle in a secure position in the cab of the vehicle where it is not likely to dislodge and cause injury to vehicle occupants in an accident or crash stop situation A suitable location would be on the floor behind the driver s or passenger s seat gt If the LycoLoader is not operating correctly for any reason contact Healy Group PIL parts and service 02 9525 5522 Fax 02 9525 5513 Email info healygroup com au APPENDIX 1 LONGITUDINAL UNDER TRAY SUPPORTS TRAY BRACKET HEX BOLTS Mie x 75mmL COACH BOLT Mle x 60mmL UTE TRAY 12mm NYLOC NUTS Figure 10 Under Tray Supports Left Hand Side FIXED TO THE TRAY WITH THE LOAD SPREAD EVENLY UNDER TRAY SUPPORT IT IS IMPORTANT TO ENSURE THE LYCOLOADER IS SECURELY LONGITUDINAL UNDER TRAY SUPPORTS MUST NOT BE USED ON TRAY BODIES WITH LONGITUDINAL WOODEN OR ALUMINIUM FLOORS UNDER TRAY SUPPORTS MUST BE MOUNTED PERPENDICULAR TO THE DIRECTION OF ANY JOINTS IN THE FLOOR 5 25 9 Mark and Drill holes for bolts in both the tray and support 12 5 hole The Coach Bolts should be placed approximately 50mm from the end opposite end to the existing slots of the Under Tray Support ensuring the holes clear the under tray braces Insert the 12mm Coach Bolts thru the drilled holes on both sides Place the Spacers Item 19 under
11. rm needs to be completed and accompany any invoice for the warranty claim 4 Lyco will pay the cost of parts and or reasonable costs of labour actually incurred in repairing the faulty component s by the customer or an agent Usually Lyco will supply any replacement parts from its own stock Warranty repairs will be completed to Healy Groups satisfaction 5 Non warranty work will be repaired and charged out at commercial rates Freight and postage incurred to complete warranty claims is the responsibility of the customer Freight should be with Healy Groups nominated carrier as Healy Group will only reimburse freight costs incurred with Healy Groups nominated carrier 7 Travelling for warranty work is the responsibility of the customer In its absolute discretion Healy Group may pay travelling costs associated with the warranty claim No labour will be paid for the time that travelling is claimed 8 Warranty claims for products damaged in freight will not be accepted The risk for damage loss or delays in freight is the sole responsibility of the buyer This is detailed in section 5 1 of the Terms and Conditions of Sale document Credit Application The only exception to this is where insurance has been taken out and paid for by the buyer or other written arrangements have been agreed with Healy Group at time of order Replaced parts and components are the property of Healy Group Replaced parts are to be returned to Healy Gro
12. s latch cannot be adopted for use with the side attachment plate the existing latch may need to be removed and discarded and replaced with a new latch arrangement such as the one supplied in the Side Attachment Kit part no LL Side Attach
13. saykisapsusqaspusya 9 LOCATINGTHELYCOLQADER L baa bau s i ha suhu AS 9 INSTALLING THE TRAY BRACKETS S us wana BS eet tate tesa eee eee 10 INSTALLING THE isso seccsscesssescgslecussdesssscoescenecsgedssesontossesssassen sued savesbcodbsescebeseysscnsnegsessaseess 11 INSTALLING THE TENSION 12 ATTACHING THE TENSION STRAPS cereo oeei 13 OP RA ON au s unaq n Sa 14 APPENDIX 1 LONGITUDINAL UNDER TRAY SUPPORT S 15 APPENDIX 2 SIDE CONNECTION 17 APPENDIX 3 SIDE ATTACHMENT FOR OTHER TRAY 19 Date of issue 23 04 14 Page 2 GENERAL SAFETY WARNINGS REGARDING FITMENT Do not fit the Lycoloader to damaged or structurally unsound tray bodies e g those with corroded floor and or structural members or damaged corroded timber floors Do not fit the LycoLoader to tray bodies with longitudinal timber floors unless transverse reinforcement is added beneath the floor to spread the load across the floor boards Do not drill above wiring or componentry located directly under the tray body GENERAL SAFETY WARNINGS FOR OPERATION lt lt
14. tem 6 to Item 2 3 with the Item 12 Bolt 8mm x 25mm Long 7 Repeat for both sides SAdAL AVAL 3D3 2 119 3015 STIV130 ASHLANA 303 2 335 3189311d4d3V 38 AVW LIA LNSWHOVILY 3015 1 314181 ANY ADJ 318V93114dV AINO SI 4135 SIHL 2 3 V 1 9 Figure 11 Side Attachment example APPENDIX 3 SIDE ATTACHMENT FOR OTHER TRAY TYPES Required for trays with dropsides If both the Standard Kit and Side Attachment Kit cannot be fitted to the tray an alternative side attachment will have to be developed and fitted for two reasons 1 To fill the gap between the outer edge of the LycoLoader Tray Bracket and the tray body s existing dropside and 2 provide a method for securing the end of the tray body s dropsides to the end of the tray Side Attachment Plate Method of either 17 Locking existing dropside catch to side attachment plate OR Attaching a new latch to dropside and new retainer to side attachment plate Figure 12 Fabricated Attachment for to Secure Dropsides This can be done by fabricating a side attachment plate to suit the tray body concerned and then adding a suitable bracket to engage and retain the existing latch on the end of the tray body s dropside If the existing tray body
15. the tray on the 12mm Coach Bolts Place the Under Tray Supports under the tray onto the 12mm Coach Bolts Place a 12mm Washer onto the Coach Bolt followed by a 12mm Nyloc Nut and tighten to a torque of 25 to 30 Nm Drill a 12 5mm hole along v groove in each Tray Bracket Item 2 4 Item 3 75mm or as determined to clear the under tray braces see Figure 3 from the back edge of the tray bracket Place the Left Hand Tray Bracket above the drilled holes on the left hand side of the ute Place 12mm Zinc Plated Washer Item 13 onto a 12mm x 75mm Bolts Item 9 Insert the Bolt thru the Tray Bracket and Tray Repeat for both holes Place the Spacers Item 19 under the tray on the 12mm x 75mm Bolts 10 Place 12mm Zinc Plated Washer Item 13 on each bolt followed by a 12mm Nyloc Nut 15 and tighten to a torque of 25 to 30 Nm Note It may be necessary to file the holes square to ensure the coach bolts sit flat against the floor of the tray body Ensure that the Spacers Item 19 and Under Tray Support 5 are installed on the Right Hand Side as well prior to tightening the bolts and nuts Refer to Installing the Main Assembly to complete the installation of the LycoLoader APPENDIX 2 SIDE CONNECTION The LycoLoader comes with 2 adjustable side mounting plates for attachment between the LycoLoader Tray Brackets and the tray body s existing dropsides These plates are suitable for tray widths between 1803m
16. up as directed on the Application for Warranty form A NOTE TO OWNERS Please take time to fill in the warranty card and return it to Healy Group PIL At the address shown on the front of card Healy Group Parts amp Service Division If any parts are missing see Parts List on 7 from the LycoLoader Package please contact Healy Group Note Delivery of the parts will be arranged using express post the LycoLoader is not operating see Operation on Page 13 correctly for any reason contact Healy Group Healy Group P L 4 12 Northumberland Rd Caringbah NSW 2229 02 9525 5522 Fax 02 9525 5513 Email info healygroup com au PARTS LIST The LycoLoader Package should contain DESCRIPTION General Assembly Tray Bracket Right Hand Tray Bracket Left Hand Tension Straps Under Tray Supports angle reinforcements Mounting Plate side spacer plates Clasp Handle Bolt 12mm x 75mm Long Bolt 12mm x 65mm Long Coach Bolt Bolt 10mm x 50mm Long Bolt 8mm x 25mm Long Washer 12mm Flat Zinc Plated Washer 10mm Flat Zinc Plated Washer 8mm Flat Zinc Plated Washer 8mm Spring Zinc Plated Nut 12mm Nyloc Nut 10mm Nyloc Spacers Table 1 Parts List gt O N 5 Refer to Figure 1 on 6 for further details gt Please note that a Side Attachment Kit or some other
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