Tommy Gate G2 dual drive G-330 User manual

Angle Iron
Preparing the Gate
1. Remove the mounting hardware which is banded to the liftgate.
2. Verify mounting bracket kit (Figure 1 and Table 1).
Figure 1: Part Identification.
Upright
Bracket Plates
Angle Iron
LEFT BRACKET
(RIGHT NOT SHOWN)
G-330 BOLT
KIT
BACKER
PLATE
BOLT
KIT G-330
PART#12800
FILLER STRIP
BOLT-ON
GUSSET
Installing the Bolt-on Gussets
1. Install the eight (8) 3/8" x 1" button head bolts, lock washers, and nuts in the position shown for your configuration (Figure 3).
· bolt-on gussets and button head bolts go to the outside of the 1/4" x 1" strip.
Note: The extra hole in the bolt-on gusset is always below the 1/4" x 1" strip (Figure 4).
Note: If gussets are already welded to the uprights, you will need a gusset extender kit (part number 6335).
Upright
Extra hole below strip
1/4" x 1" strip
welded to uprights
Figure 2: Complete liftgate.
Bolt-on Gusset
1-3/16
18-1/2"
3-1/8"
3. Support the liftgate; it will not stand upright without the angle irons.
4. Unbolt the two (2) angle irons attached to the liftgate uprights (Figure 2).
5. Unbolt the long angle iron from the bottom of the liftgate (if equipped).
6. Remove the two (2) bracket plates attached to the liftgate (Figure 2).
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CIRCUIT
BREAKER KIT
Pickup Lift Mounting Instructions G-330
Figure 3: Top view of liftgate bolt-on gussets.
3/8" Lock Washer
3/8" x 1" Button Head Bolt
3/8" Nut
59.94"
Top View
Bolt-on Gusset
Figure 4: Liftgate requiring bolt-on gussets.
dual drive
R
SELF DRILL
SCREWS
Table 1: Parts List.
19094 Standard Pickup Bracket Bolt Bag Kit
T-330 Bolt Bag Kit
T-330 Left Corner Bracket
12GA.x3"x9" Ford Backer Plate
12GA.x5.28"x19.5" G-330 Filler Strip
T-330 Right Corner Bracket
T-330 Bolt-on Gusset
2
16487
19999
312799
25085
16488
DESCRIPTIONQTY. PART NO.
13174
116296 Filler Strip Hardware Kit
Circuit Breaker Bracket Kit
114196
Fullsize Dodge/Ram Trucks-
1500: 2002-2018 (Includes 2019-Present "Classic")
2500 & 3500: 2003-Present (Excludes 2013-Present DRW)
(Excludes "Ram Box")
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1. Remove the tailgate. The tailgate hardware does not need to be removed.
2. Unbolt the tie down hooks (Figure 5).
If the tie down hooks are welded in, they do not need to be remove.
3. Remove the rear bumper mounting bolts and bumper.
The bumper and bumper mounting brackets cannot be remounted after the liftgate is installed.
Note: The factory tube and/or receiver hitch should not be removed.
The lift gate is designed to fit over the factory receiver hitch.
Modifying the Tail Light Mounting
Note: This modification must be completed before the liftgate is installed so that the tail light
bulbs can be replaced without removing the liftgate.
Note: This modification may not be needed. Check if the tail light screws can be accessed
through the clearance holes in the liftgate gussets.
1. Remove the two (2) factory tail light screws from each tail light lens (Figure 6).
The screws will not be reused after the modification.
2. Carefully Drill a 9/64" hole through each tail light lens and internal
sheet metal (Figure 6).
3. Carefully Drill a 3/16" hole through each tail light lens only, for screw clearance.
Note: Do not install the tail lights now if 1500 lb application.
4. Apply clear silicone sealant to the 3/16" holes in the tail light lenses
and stainless self-tapping screws.
5. Install a stainless self-tapping screw, supplied, into each 9/64" hole to hold
the tail light lenses in place (Do not over-tighten).
Figure 5: Remove Hardware.
Preparing the Truck
G-330
chassis frame
Unbolt brackets from
Tailgate Stay
Tailgate
Tie Down Hook
Figure 6: Tail light modification detail (if needed).
Modifying the Spare Tire Crankshaft
Note: This modification must be completed before the liftgate is installed.
Note: This modification allows access to the spare tire crank mechanism after the liftgate is installed.
1. Remove the plastic spare tire access grommet from the back of the truck box (Figure 7).
2. Remove the plastic grommet in the rear cross member of the truck frame (Figure 7).
3. Drill a 1-1/4" diameter hole, centered above the existing tire access hole, and
2-5/8" down from the top of the box (Figure 8). Some trucks have a vibration
damper that conflicts with the drilled hole, the damper can be removed.
Plastic
Grommet
Holder
Spare Tire
Ø1-1/4"
2-5/8"
existing tire
access hole
Figure 7: Spare tire access modification.
Figure 8: Spare tire access hole location.
Note: The filler strip must be mounted on the liftgate before the liftgate is installed.
Note: The filler strip will fill the gap between the liftgate and the truck bed.
1. Arrange the three (3) 12ga. x 5-9/16" x 19-1/2" G-330 filler strips end to end with the
short flange flat against the back of the liftgate mainframe and the top even with the
top of the top of the mainframe.
2. Avoid obstructions inside the mainframe box while attaching filler strips.
3. Attach the three (3) filler strips to the mainframe with the provided self drilling screws.
Installing the Filler Strip
Figure 9: Filler strip placement.
Centered above
Self-tapping
Tail Light
Factory
Screws
Screw
Drilled hole
Stainless
Tail Light
Lens
Liftgate Gusset
Clearance Hole
Approx. 3" for Class 4 Hitch
Approx. 4" for Class 5 Hitch
Pickup Lift Mounting Instructions
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Filler Strip
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G-330
Removing the Knockouts
Note: This modification must be done before the liftgate is installed, so the liftgate will fit over the Dodge factory receiver hitch.
1. Verify how many of the knockouts need to be removed.
This can be done by looking at the Installing the Lower Mount sections on page 8.
2. Remove the 2-1/4" knockouts from the bottom of the mainframe using a screw driver and
a pair of pliers (Figure 10).
Note: If the liftgate you are mounting does not have the knockout holes, they must be added.
Contact Tommy Gate for instructions (712-847-8000).
Knockouts
Figure 10: Knockout hole location.
Installing the Liftgate
1. Position the mounting brackets into the truck bed in front of the corner posts (Figure 11).
Do not drill holes for mounting brackets at this time.
2. Position the Tommy Lift into the bed opening. The liftgate should be:
z Aligned with spare tire tube.
z Centered in the opening.
z Flush with the truck bed floor.
z In a vertical position (level with the ground).
3. Hand tighten each mounting bracket to the liftgate gussets using the supplied:
z (3) 3/8"x1" hex head bolts on the bracket-side (Figure 11).
z (3) 3/8" lock washers, and (3) 3/8" nuts on the gusset-side (Figure 11).
4. Allow the liftgate to hang, supported by the corner posts.
5. Hold the bracket against the corner post.
6. Check for obstructions before drilling in the next step.
7. Drill two (2) 3/8" holes into the truck bed floor using two holes in the bracket as a guide.
Choose two of the four holes provided with no obstructions on the underside (Figure 12).
8. Fasten each bracket to the truck box using the supplied:
z (2) 3/8"x1" hex head bolts on the top-side (Figure 12).
z (1) backer plate, (2) lock washers, and (2) hex nuts on the under-side (Figure 12).
Note: Ensure that the bracket contacts the top of the corner post. One or two 3/8" flat
washers may be needed between truck bed and bracket for this purpose.
Note: Backer plates may need to be trimmed to fit.
9. Adjust the liftgate so the platform is level from front to back.
Check the clearance between the truck tail light lenses and the liftgate.
10. Tighten the bolts securing the liftgate gusset to the mounting brackets.
The lock washer split must not be in the gusset slot when tightening bolts.
Figure 11: Mounting bracket and liftgate.
Right Mounting
Bracket
3/8" Lock Washer
3/8" Nut
Liftgate Gusset
3/8 X 1" Bolt
Figure 12: Mounting bracket and backer plate.
Bracket
Backer Plate
3/8" Lock Washer
3/8" Nut
3/8x1" Bolt
Through Truck Bed
Drilled 3/8" Holes
Mounting
Inner Box Side
Corner Post
Note: Liftgate not shown for clarity.
Pickup Lift Mounting Instructions
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3/8" Washer
(if needed)
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39-1516"
8"
Dodge access hole in
the rear of the liftgate
Front of Liftgate
mainframe
G-330
Adding Additional Support ( 1500 lb Application Only)
Note: Additional bracket support is required at this capacity.
1. Locate the existing 3/8" hole in the mounting bracket (Figure 13).
2. Check for obstructions before drilling in the next step.
3. Drill a 3/8" hole in the inner box side, using the bracket's hole as a guide.
If a hole already exists, be sure to use the provided backer plate in the next step.
4. Fasten the mounting bracket to the inner box side using the supplied (Figure 13):
z (1) 3/8" lock washer and (1) 3/8" nut on the bracket-side.
z (1) 3/8"x1" hex head bolt, (1) 3/8" flat washer, and (1) backer plate on the truck-side.
5. Repeat for the other mounting bracket.
6. Install tail light lenses.
Figure 13: Additional support location.
Checking Spare Tire Access
Note: There is a hole in the mainframe that provides access to the spare tire crank mechanism.
1. Remove the box cover by removing the 5/16" hex head nuts (Figure 14).
2. Remove and Discard the black plastic plug from the mainframe at the location shown (Figure 15).
3. Verify spare tire access operation by inserting the spare tire crank rod through the access hole.
Figure 15: Spare tire access.
Driver's Side
Note: Liftgate not shown for clarity.
3/8" Lock Washer
3/8" Nut
3/8x1" Bolt
3/8" Flat Washer
Ø3/8" Hole
Inner Box Side
Pickup Lift Mounting Instructions
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Backer Plate
R
Figure 14: Box cover locations.
(3) 5/16" Hex
Nuts
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1. Install the circuit breaker on the circuit breaker bracket with 1/4" screws and nuts (Figure 17).
2. Install the circuit breaker on the vehicle fender, inside the engine compartment away from moving parts.
Leave enough room for the power cables to be installed and so that the circuit breaker can easily be reset.
3. Loosen the strain relief on the back of the liftgate mainframe (Figure 18).
Vent Plug
Pump & Motor
Figure 16: Vent plug.
Routing the Power Cables
G-330
Figure 18: Electrical routing.
Figure 17: Circuit breaker bracket.
1. Unscrew the solid plastic plug from the pump reservoir. The box cover should already be off.
Note: The hydraulic system has already been filled with the proper amount of hydraulic oil so do not add any oil at this time.
2. Attach 12 volts from a battery to the liftgate power cables (no battery chargers).
3. Push the hidden "Power On" switch (Figure 19). The amber "Power On" LED will illuminate.
4. Push the hidden "Liftgate Activated" switch twice within one second. The red "Liftgate Activated" LED will illuminate.
Note: With both lights on, the liftgate can be raised or lowered. If not used for 90 seconds, the control will automatically shut off.
5. Push the toggle switch down to lower the liftgate to the ground.
6. Remove the following from inside the liftgate mainframe:
z Owner/Operator Manual
z License plate light
z License plate light hardware
z (1) Vent plug
z (1) 150 Amp manual reset circuit breaker
z (4) Copper lugs
z (2) License plate nuts and screws
z (1) Padlock with keys
z (5) 3/8" plastic plugs
z (1) Drop away pin
z (1) Lower mounting kit
7. Install the vent plug provided into the pump reservoir (Figure 16).
Preparing the Gate for Wiring
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Pickup Lift Mounting Instructions
To
Liftgate
Reservoir
Circuit Breaker
Battery
Strain Relief
Top View of Truck
Liftgate4ga Power Cable
-+
Positive Lead
Circuit Breaker
Battery*
Positive Lead
Negative Lead
*Verify battery polarity. Older trucks may have
different battery orientation.
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G-330
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4. Pull the power cable (coiled up in the liftgate mainframe) carefully through the strain relief.
Leave approximately two (2) inches of slack inside the liftgate mainframe (Figure 18).
5. Tighten the strain relief.
6. Route the power cables along the frame (Figure 18) to the battery following
the Tommy Gate Recommended Electrical Wiring Guidelines.
7. Pull the excess cable beyond the battery.
8. Separate the positive(+) and negative(-) leads.
9. Cut the positive(+) lead to the length required to reach the auxiliary (AUX) terminal of the circuit breaker.
10. Cut the remaining pos.(+) lead long enough to reach from the circuit breaker battery (BAT) terminal to the pos.(+) battery terminal.
11. Cut the negative(-) lead to a length required to reach the negative battery terminal.
IMPORTANT: The pump and motor unit for this lift can require significant electrical power at 12 volts D.C.
Be sure that the negative(-) ground lead is connected to the negative(-) terminal of the vehicle battery.
12. Install the copper lugs and heat shrink tubing on all required ends.
13. Connect the circuit breaker and battery as outlined in the Tommy Gate Recommended Electrical Wiring Guidelines and wiring
diagram (Figure 19).
Routing the Power Cables (continued)
Pickup Lift Mounting Instructions
Figure 19: Wiring diagram.
Pos.
-
Neg. +
IMPORTANT
DN
hydraulic lift
UP
ON
POWER ACTIVATED
LIFTGATE
The original
Blinking amber
LED indicates low
voltage condition "Power On" Amber LED-
Enabled when "on"
"Liftgate Activated" Red LED -
Enabled when "on"
"Liftgate Activated" Hidden
Switch - Press twice within one
second to activate timer
"Power On" Hidden Switch - Press
once to arm, press again to disarm
Brown - Release
Black - Ground
Green -
Raise
AWG #18
Wires
Ground Cable
AWG #4
Main Power Cable
AWG #4
"BAT" Terminal
"AUX" Terminal
150 Amp
Manual Reset
Circuit Breaker
Mounting Hole
Pump and Motor
Common Ground
"Release"
Solenoid
Valve
Main Power Cable
AWG #4
Pump and Motor
Vehicle
Battery
Yellow -
Release
"Raise/Lower" Toggle Switch
Welding Note: Disconnect all battery cables.
Always disconnect the ground cable first. Attach the
welding ground to the truck rather than the liftgate.
Note: If gates are not wired
in accordance with this diagram
your warranty will be void.
Please read and follow all
directions before proceeding
IMPORTANT
IMPORTANT
"Raise" Solenoid
Motor Contactor
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Red - +12VDC
Supply for Control
System
Inline Fuse
Quick Disconnect

Pickup Lift Mounting Instructions
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G-330
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"Raise" Contactor
Legend
Contactor - Normally Open Contacts
Motor
Solenoid/Contactor - Coil
Circuit Breaker
Battery Cable
Wire
Grounded through pump body.
"Lower"
Valve
"Raise"
Contactor
M
UP
DOWN
M
Eyelet Terminal
Splice
Red (12V)
Blue (24V)
Green
Brown
Black
Black
Red
Battery
+12V
or +24V
Battery
GND
Ladder Logic/Wiring Diagram
Pump
Motor
Fixed Control
Red
Red with Black Stripe
On/Off/
Activate
Fuse
Fuse
Red Red
Quick Disconnect
Red
24V
M
Pump
Motor
BKBK RD/BK
Abbreviations
BK: Black
RD/BK: Red with Black Stripe
Violet
"Raise"
Contactor
Green Violet
24V
BK

1. Install the two (2) square plastic insert nuts for the license plate into the square holes on the liftgate.
2. Install the license plate using the two (2) stainless steel screws provided.
3. Install the license plate light into the hole provided.
4. Connect the license plate light to the vehicle's wiring following the Tommy Gate
Recommended Electrical Wiring Guidelines. The license plate light wires can be
run through the strain relief in the back of the liftgate.
Note: Additional wire may need to be spliced into the license plate light circuit to reach the connection point.
Note: All electrical splices should be heat shrunk for corrosion protection.
5. Install the 3/8" round plastic plugs into the empty holes in the bottom of the uprights.
6. See the Owner's / Operator's Manual if drop away feature is desired.
7. Install the "Do's and Do Not's" decal in a highly visible area in the vehicle cab.
This decal is with the Owner's / Operator's Manual.
8. Reinstall the spare tire, if previously removed.
Finishing the Liftgate Installation
G-330
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Pickup Lift Mounting Instructions
Installing the Lower Mount (Class 4 Hitch)
1. Assemble the supplied hardware through the center hole in the bottom of the liftgate
mainframe and the center hole in the factory hitch plate on the truck (Figure 20).
1/2" Lock Washer
1/2" Nut
Washer Plate
1/4"x2-1/2"x2-1/2"
1/2"x3" Bolt
Figure 20: Lower bracket support (Class 4 hitch).
1/4"x2-1/2"x2-1/2"
Washer Plate
Installing the Lower Mount (Class 5 Hitch)
Washer Plate
1/2" Lock Washer
1. Assemble the supplied hardware through the outer two holes in the bottom of the liftgate
mainframe and the two holes in the factory hitch plate on the truck (Figure 21).
2. Add the supplied 7GA bracket plates between the liftgate and the factory
hitch plate to raise the top of the liftgate to bed height, if needed.
Note: The bracket plates will need to be modified.
Note: Be sure the bracket plates will not interfere with the spare
tire or backup bar, if one will be installed.
1/2" Nut
1/2"x2" Bolt
Figure 21: Lower bracket support (Class 5 hitch).
7GA Bracket Plate
Washer Plate
(if needed)
Trim as needed
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Figure 22: Padlock location.
Padlock
Latch Pin Latch
G-330
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Pickup Lift Mounting Instructions
CAUTION: Keep all foreign objects (body parts, tools, load weights, etc) out of the liftgate mainframe and away from pinch
points at all times when operating the liftgate.
1. Check operation of the safety control for proper lift operation.
Be sure the control shuts off automatically after 90 seconds of not being used.
2. Raise and Lower the unloaded platform on a flat surface looking for proper operating speed and alignment with the ground.
3. Load the platform with the rated capacity and Measure the time necessary to raise the platform.
The platform should raise at roughly 2-3 inches per second.
4. Examine the platform for any downward creep.
5. Time the lowering operation with the platform still loaded.
The load should descend at roughly 7-9 inches per second.
6. Remove the load from the platform and Examine the liftgate and vehicle for any problems
such as hydraulic oil leaks, loose wiring, etc.
7. Reinstall the box cover.
8. Close and Latch the platform.
9. Lock the padlock through the hole in the latch pin (Figure 22).
10. Place Owner's / Operator's Manual and padlock keys in the vehicle.
Testing the Operation of the Liftgate
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G-330
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Your Tommy Gate has been primed with a gray polyurethane and painted with a black semi-gloss polyurethane topcoat to protect it
from the environment. No additional paint is required unless shipping or installation damage or outdoor storage exposure has
deteriorated the Tommy Gate paint. Tommy Gate will not be responsible for shipping or installation damage or outdoor
storage exposure that has marred or otherwise deteriorated the Tommy Gate paint.
If you need to refinish the liftgate you should do the following:
1. Remove any dirt, oil, grease, salt, or other contamination by washing with a mild detergent solution.
2. Rinse thoroughly with fresh water and allow to dry.
3. Lightly Scuff Sand the Tommy Gate topcoat.
4. Sand and Spot Prime any area of the Tommy Gate paint that shows signs of damage or deterioration.
5. Mask off all safety decals, cylinder shafts and vents before painting.
WARNING: Paint overspray on the cylinder shaft(s) or vent(s) will damage the cylinder seals and void warranty.
6. After proper cleaning and surface preparation, Apply desired finish coat per paint manufacturer's recommendations.
7. Remove the masking from the safety decals and cylinders.
8. Check to ensure that all decals are clean and legible. Additional decals are available from the factory, if needed.
Painting the Liftgate (if needed)
Pickup Lift Mounting Instructions
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Tommy Gate Recommended Electrical Wiring Guidelines TOMMY GATE
The original
hydraulic lift
®
TOMMY GATE
The original
hydraulic lift
®
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WIRE ROUTING
(1) When routing wires, avoid heat (above 180ºF), abrasion, vibration, metal edges, screws, and trim fasteners. If
such routings are not possible, protective devices must be used. If wires must cross a metal edge, the edge
should be covered with a protective shield and the wiring fastened within 3 inches on each side of the edge.
(2) Grommets must be used where wires pass through holes in sheet metal, castings, and / or frame rails. Do not
bend wires in a radius smaller than 10 times the wire diameter.
(3) Routing wires into areas exposed to wheel wash should be avoided. If this cannot be avoided protective shields
are required to protect the wires from stones, ice, salt and water damage. Provide a drip loop to prevent
moisture from being conducted into switches, relays, circuit breakers, and fuses.
(4) Wires should be supported every 18 inches with plastic zip ties or rubber-lined clips.
(5) Wires must be routed to clear moving parts by at least 3 inches unless positively fastened or protected by a
conduit. If wiring must be routed between two members where relative motion can occur, the wiring should be
secured to each member, with enough wire slack to allow flexing without damage to the wire.
(6) Maintain at least a 6 inch clearance from exhaust system components. If this is not possible, high temperature
insulation and heat shields are required. Existing OEM heat shields, insulation, and wire shielding must be
maintained.
(7) Do not route or attach electrical wires to fuel lines. Route electrical wires at least 1-1/2 inches away from the
engine.
BATTERY, WIRE, TERMINALS, AND CONNECTORS
(1) Wire attachments at the battery must be protected from tension loads so there is no undue strain on the battery
terminals. Wires should be routed down rather than horizontally from the terminals with no sharp bends
adjacent to the connections.
(2) Battery power for your Tommy Gate should come directly from the battery through the supplied circuit breaker
or fuse. The circuit breaker or fuse should be installed as close to the battery as possible.
(3) Do not splice battery cables. If splicing is necessary, the most durable splice joint will be 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 a gauge at least equivalent to the circuit being lengthened. Do not use electrical tape.
(4) Battery cable terminals will be bare metal barrel crimped or flow-soldered and covered with adhesive lined heat
shrink tubing.
(5) Use wire connectors with locking features such as positive locking, inertia locking, bolt together, and soft
mold-over with locking external retainers.
GENERAL
(1) All frame contact areas must be wire brushed to bare metal, free of paint, dirt, and grease. Frame connections
must be made using hardened flat washers under the bolt head and lock nuts. Corrosion preventive grease or
compound is to be applied to the terminal area of the frame connection.
(2) Frame cross members are not recommended as part of the ground return.
(3) All circuit breakers and fuses should be located in one easily serviceable location with a means provided for
identification of circuit function and current rating. Do not put circuit breakers or fuses in the vehicle cab.
(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 a 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 trouble free service. Failing to incorporate the above
guidelines will result in a voided warranty. Non-compliance with the guidelines above may result in a failure of
electrical components, shutdown of engines, loss of backup brake systems, and the possibility of fire.