Tommy Gate Original TG-67 User manual

1. Remove the mounting hardware which is banded to the liftgate.
2. Verify mounting bracket kit (Figure 1 and Table 1).
Preparing the Gate
Figure 1: Part Identification.
Toyota-
Tacoma: 2005-present
Mounting Angle Iron
2
PART NO.
Table 1: Parts List.
122801
12278
12279
1
2
1
QTY.
TG-67 Bolt Bag Kit
TG-67 Right Bracket
TG-67 Left Bracket
DESCRIPTION
TG-67
TG-67 Lower Bracket Plate
12282
15262
Preparing the Truck
1. Remove the tailgate and hardware shown (Figure 2).
2. Support the rear bumper and hitch to keep them from falling while removing the mounting bolts.
3. Remove the rear bumper, bumper mounting brackets, and hitch.
Note: The tailgate, hardware, rear bumper, and hitch cannot be remounted
after the liftgate is installed.
Figure 2: Remove Hardware.
Cargo Strap Loop
Tailgate
Unbolt brackets from
chassis frame
Original Series Pickup Lift Mounting Instructions
Ø1-1/4"
Figure 3: Spare tire access hole location.
Center of Truck Bed
2-1/2"
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. Check for obstructions before drilling in the next step.
2. Drill a 1-1/4" diameter hole, 1-1/4" to the left of the center of the bed,
and 2-1/2" down from the top of the bed (Figure 3).
3. Remove the box cover by removing the 5/16" hex head bolts.
4. Check for obstructions before drilling in the next step.
5. Drill a 2" diameter hole, in the back of the liftgate in the location shown,
if needed (Figure 4).
Modifying the Spare Tire Access
1-1/4"
23-5/16"
Access holes in the
rear of the liftgate
Ø 2"
2-1/2"
Driver's Side
Front of Liftgate
Figure 4: Spare tire access hole location in liftgate.
TG-67
PART#12281
BOLT KIT
RIGHT BRACKET
(LEFT NOT SHOWN)
MOUNTING
ANGLE
IRON
LOWER
BRACKET
PLATE
9-5/8"
15-1/2"
DPN: 095098 Rev 3 4-12-23
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Original Series Pickup Lift Mounting Instructions
Figure 6: Box cover location.
Head Bolts
(2) 5/16" Hex
Original Series
1. Remove the truck bed bolts at the rear of the truck bed, two per side (Figure 5).
2. Position the supplied 3/8" spacers over the mounting holes near the wheel wells,
one per side (Figure 5).
3. Position the mounting brackets in the truck bed over the truck bed mounting holes (Figure 5).
4. Install the factory bed bolts in the mounting brackets (hand tight only).
5. Position the Tommy Lift into the bed opening. The liftgate should be:
·Centered in the opening.
·Flush with the truck bed floor.
6. Attach liftgate gussets to the mounting brackets using the supplied (4) 1/2"x1-1/4" hex
head bolts, lock washers, and flat washers on the bracket-side (Figure 5).
7. Adjust the liftgate so that it is level with the ground.
Add 1/2" washers between the liftgate and bracket, if needed.
8. Tighten all bracket and bed bolts.
Figure 5: Mounting bracket and liftgate.
Installing the Liftgate
Bracket
Liftgate
Left Mounting
Gusset
Bracket
Right Mounting
TG-67
3/8" Spacer this hole
(one per bracket)
Note: There are holes in the mainframe that provide access to the spare tire crank mechanism.
1. Remove the box cover by removing the 5/16" hex head bolts or nuts (Figure 6).
2. Verify spare tire access operation by inserting the spare tire crank rod through the access hole.
Checking the Spare Tire Access
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Vent Plug
Pump&Motor
Figure 7: Vent plug.
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 8). 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:
·Owner/Operator Manual
·(2) License plate lights
·(1) Vent plug
·(2) Latch balls with studs
·(1) 150 Amp manual reset circuit breaker
·(4) Copper lugs
·(2) License plate nuts and screws
·(1) Padlock with keys
·(1) Lower mounting kit
7. Install the vent plug provided into the pump reservoir (Figure 7).
Preparing the Gate for Wiring
TG-67
Original Series Pickup Lift Mounting Instructions
DPN: 095098 Rev 3 4-12-23
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Reservoir

Page 4
1. Install the circuit breaker on the vehicle fender, firewall, or other location 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.
2. Loosen the strain relief on the back of the liftgate mainframe.
3. 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.
4. Tighten the strain relief.
5. Route the power cables along the frame to the battery following the Tommy Gate Recommended Electrical Wiring Guidelines.
6. Pull the excess cable beyond the battery.
7. Separate the positive(+) and negative(-) leads.
8. Cut the positive(+) lead to the length required to reach the auxilliary (AUX) terminal of the circuit breaker.
9. Cut the remaining pos.(+) lead long enough to reach from the circuit breaker battery (BAT) terminal to the pos.(+) battery terminal.
10. Cut the negative(-) lead to the 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.
11. Install the copper lugs and heat shrink tubing on all required ends.
12. Connect the circuit breaker and battery as outlined in the Tommy Gate Recommended Electrical Wiring Guidelines and wiring
diagram (Figure 8).
Routing the Power Cables
TG-67
Original Series Pickup Lift Mounting Instructions
DPN: 095098 Rev 3 4-12-23
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Figure 8: 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
Red - +12VDC
Supply for Control
System
Inline Fuse
Quick Disconnect

Page 5
Original Series Pickup Lift Mounting Instructions
DPN: 095098 Rev 3 4-12-23
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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
TG-67

Finishing the Liftgate Installation
3/8" Threaded Hole
3/8" Stud and Knob
Figure 11: Original Series platform latch knob.
Figure 10: Lower bracket support.
Installing the Lower Mount
IMPORTANT: Do not install a liftgate on a pickup without installing the lower mount.
1. Install the two (2) mounting angle irons to the bottom of the liftgate (Figure 9).
Select the holes in the liftgate that position the angle irons adjacent to the truck frame rails.
Note: Nuts have been welded to the inside of the liftgate to accept the bolts.
Note: If the liftgate already has a long angle iron, use it in place of the two mounting angle irons.
2. Bolt the bracket plates to the truck frame (Figure 9).
Use the factory bumper/hitch bolts.
3. Tack weld the bracket plates (see welding note at right), and the mounting
angle irons together.
4. Remove the tacked lower brackets from the truck.
5. Weld all seams with a heavy weld where the bracket plates meet the mounting angle irons.
6. Bolt the completed brackets back to the truck frame and bottom of the liftgate.
Note: The lower mount is of great importance because it adds additional support to the liftgate.
Bracket
Irons
Mounting
Angle
Plates
RATHER THAN THE LIFTGATE.
BATTERY CABLES. ALWAYS DISCONNECT
THE WELDING GROUND TO THE TRUCK
THE GROUND CABLE FIRST. ATTACH
WELDING NOTE!!! DISCONNECT ALL
IMPORTANT
Figure 9: Mounting angle iron location.
Mounting Angle Iron
1/2"x1-1/4" Bolt
1/2" Lock Washer
1/2" Nut
TG-67
Original Series Pickup Lift Mounting Instructions
DPN: 095098 Rev 3 4-12-23
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1. Install the two (2) knobs on the platform latches (Figure 11).
2. Install the two (2) square plastic insert nuts for the license plate into the square holes
on the liftgate.
3. Install the license plate using the two (2) stainless steel screws provided.
4. Install the license plate light(s) into the holes provided.
5. Connect the license plate light(s) to the vehicle's wiring following the Tommy Gate
Recommended Electrical Wiring Guidelines. The license plate light wire(s) 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.
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.

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 reach the bed height within a 20-second time interval.
4. Examine the platform for any downward creep.
5. Time the lowering operation with the platform still loaded.
It should take about 1/2 second per inch of bed height for the platform to reach the ground.
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 platform (Figure 12).
10. Place Owner's / Operator's Manual and padlock keys in the vehicle.
Testing the Operation of the Liftgate
Platform Lid End
Figure 12: Padlock location.
Latch
Padlock
Original Series
Original Series Pickup Lift Mounting Instructions TG-67
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Page 8
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)
Original Series Pickup Lift Mounting Instructions TG-67
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Tommy Gate Recommended Electrical Wiring Guidelines TOMMY GATE
The original
hydraulic lift
®
TOMMY GATE
The original
hydraulic lift
®
DPN: 095098 Rev 3 4-12-23
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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.