G1'dual drlve "' and Original Series Mounting Instructions Service, Utility, Flatbed, Stake and Van Body Preparing the Gate 1. Measure the body opening, the overall width, and the maximum bed height of the truck (Figure 1). Make sure you have the соттесt model of liftgate for your application. Т-49А S-400-40 2. Remove the mounting hardware which is banded to the liftgate. 3. Verify mounting bracket kit (Figures 2 and 3 and ТаЫеs 1 and 2). LEFT ВRАСКЕТ (RIGHT NOT SHOWN) BOLTBAG TRIANGLE GUSSET Figure 2: Т -49А Part ldentification. 1/4" FILLER PLATE Т-49А PART#5141 ТаЫе 1: Т -49А Parts List. QТУ. PARTNO. DESCRJPТJON 1 5012 Т-49А R.;ght Bracket 1 5011 Т-49А Left Bracket 2 9744 1/4" Filler Plate 2 6948 1/4" Triangle Gusset 1 1096 Т-49А BoltBag Кit Figure 1: Body opening measurements. BOLTBAG G2 SERIES MOUNTING EAR ORIGINAL SERIE;zз MOUNTING EAR 0.9: Figure 3: S-400-40 Part ldentification. S-400-40 PART#1019 ТаЫе 2: S-400-40 Parts List. QТУ. PART NO. DESCRJPТJON 2 1020 02 Series Mounting Ear 2 9438 S-400-40 Strap 9096 S-400 Bolt Bag Кit 2 1028 Original Series Mounting Ear 4. Support the liftgate; it will not stand upright without the angle irons- G' only. 5. Unbolt and Save the two (2) angle irons attached to the liftgate uprights- GJ only (Figure 4). 6. Remove and Save the two (2) bracket p\ates attached to the liftgate- GJ only (Figure 4). Upright Figure 4: Complete liftgate (G'Jshown). Preparing the Truck 1. Verify that there are no obstructions on the rear end rails or the end of the body. Note: If factory light packages will Ье obstructed Ьу the liftgate, optional liftgate light kits are availaыe for installation (Figure 5). 2. Remove the original tailgate, where appropriate. 3. Check for spare tire access before installing the liftgate. If necessary, remove the spare tire, modify the spare tire crank and/or the liftgate for tire access. 4. Verify the vehicle's structure. The vehicle's body or frame must support the liftgate's loads as indicated in (Figure 6). Figure 5: Factory lighting systems. 2600 lbs. t each side - о 1 2000 lbs. approx each side! 31" 12600lbs. о eachside- Figure 6: Liftgate loads that the vehicle must support. DPN: 095044 Page 1 of7 RevЗ 10-12-11
Tommy Gate Recommended Electrical Wiring Guidelines WIRE ROUТING (1) When routing wires, avoid heat (above 180 F), abrasion, vibration, metal edges, screws, and trim fasteners. If such routings are not possiыe, protective devices must Ье used. If wires must cross а metal edge, the edge should Ье covered with а protective shield and the wiring fastened within 3 inches on each side of the edge. (2) Grommets must Ье used where wires pass through holes in sheet metal, castings, and / or ftame rails. Do not bend wires in а radius smaller than 10 times the wire diameter. (3) Routing wires into areas exposed to wheel wash should Ье avoided. If this cannot Ье avoided protective shields are required to protect the wires ftom stones, ice, salt and water damage. Provide а drip loop to prevent moisture ftom being conducted into switches, relays, circuit breakers, and fuses. (4) Wires should Ье supported every 18 inches with plastic zip ties or rubber-lined clips. (5) Wires must Ье routed to clear moving parts Ьу at least 3 inches unless positively fastened or protected Ьу а conduit. If wiring must Ье routed between two members where relative motion сап occur, the wiring should Ье secured to each member, with enough wire slack to allow flexing without damage to the wire. (6) Maintain at least а 6 inch clearance ftom exhaust system components. If this is not possiыe, high temperature insulation and heat shields are required. Existing ОЕМ heat shields, insulation, and wire shielding must Ье maintained. (7) Do not route or attach electrical wires to fuel lines. Route electrical wires at least 1-1/2 inches away ftom the engine. BATTERY, WIRE, TERМINALS, AND CONNECTORS (1) Wire attachments at the battery must Ье protected ftom tension loads so there is no undue strain on the battery terminals. Wires should Ье routed down rather than horizontally ftom the terminals with no sharp bends adjacent to the connections. (2) Battery power for your Tommy Gate should соте directly ftom the battery through the supplied circuit breaker or fuse. Тhе circuit breaker or fuse should Ье installed as close to the battery as possiыe. (3) Do not splice battery саыеs. If splicing is necessary, the most duraыe splice joint will Ье bare metal barrel crimped, flow-soldered and covered with adhesive lined heat shrink tubing. Strip the wire ends making sure that individual conductor strands are not damaged. Use only rosin core solder, proper crimping tools, and wire with а gauge at least equivalent to the circuit being lengthened. Do not use electrical tape. (4) Battery саые terminals will Ье bare metal barrel crimped or flow-soldered and covered with adhesive lined heat shrink tuьing. (5) Use wire connectors with locking features such as positive locking, inertia locking, bolt together, and soft mold-over with locking extemal retainers. GENERAL (1) All ftame contact areas must Ье wire brushed to bare metal, ftee of paint, dirt, and grease. Frame connections must Ье made using hardened flat washers under the bolt head and lock nuts. Coпosion preventive grease or compound is to Ье applied to the terminal area of the ftame connection. (2) Frame cross members are not recommended as part of the ground retum. (3) All circuit breakers and fuses should Ье located in one easily serviceaыe location with а means provided for identification of circuit function and cuпent rating. Do not put circuit breakers or fuses in the vehicle саь. (4) Before welding to the chassis disconnect the battery. Also disconnect the power train, engine, valve, and transmission control modules. (5) Do not alter vehicle ignition, starting, and / or charging systems. Do not reroute engine compartment wiring. (6) Full copper circuitry and standardized polarity grounds are recommended. (7) Never increase the rating of а factory installed fuse or circuit breaker. (8) Disconnect the battery negative (ground) wire prior to any vehicle modification. Following the above guidelines will provide you with years of trouыe ftee service. Failing to incorporate the above guidelines will result in а voided waпanty. Non-compliance with the guidelines above may result in а failure of electrical components, shutdown of engines, loss of backup brake systems, and the possiьility of fire.