Tuffy 109 User manual

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INSTALLATION INSTRUCTIONS
4’, 6’ AND 8’ DRAWERS #109, #115, #123
Please read and fill out the enclosed warranty registration card to activate your warranty.
SHIPMENT CONTENTS
(1) Drawer Assembly (1) Enclosure Assembly
(1) Front Mounting Bracket (1) Rear Mounting Bracket (4) Hairpins
HARDWARE PACKAGE
(4) 3/8” Nylock Nuts (8) 3/8” Washers (4) 3/8” x 1 ½” Allen Head Bolts
TOOLS AND SUPPLIES NEEDED
•Electric drill
•1/4” and 1/2” Drill bit
•Center punch, marker, or pencil
•Tape measure
•½” Socket and ratchet
•9/16” Socket and ratchet, or wrench
•Allen wrench set (Inch)
•Silicone sealant (Recommended)
ATTENTION: THIS DRAWER HAS MANY MOVING PARTS WITH FASTENERS WHICH SHOULD BE CONSTANTLY
CHECKED TO ENSURE THEY HAVE NOT COME LOOSE. WE RECOMMEND DOING THIS AT THE TIME OF
INSTALLATION AND MONTHLY. A PARTICULARLY IMPORTANT PART IS THE SLIDE LOCK ASSEMBLY WHICH
IS LOCATED ON THE UNDERSIDE OF THE DRAWER TOWARD THE REAR. WHEN THE DRAWER IS LOCKED IT
PREVENTS THE DRAWER FROM OPENING. THESE NUTS NEED TO BE ONLY LOOSE ENOUGH TO ALLOW THE
ASSEMBLY TO ROTATE. IF THEY WORK THEIR WAY ALL THE WAY OFF YOU WILL NOT BE ABLE TO GET
YOUR DRAWER OPEN. OVER TIME THE NUTS MAY NEED TO BE REPLACED TO ENSURE THE NYLOCK IS
STILL EFFECTIVE.

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PLEASE READ ALL SAFETY WARNINGS AND INSTRUCTIONS THOROUGHLY BEFORE STARTING INSTALL
SAFETY WARNING!INSTALLATION REQUIRES 2 PEOPLE AND HEAVY LIFTING. Only use the handle
to maneuver the drawer. All fasteners will need to be periodically checked for looseness or wear. The slides should be
checked regularly for damage. The slides will need to be cleaned regularly to ensure smooth operation. Only operate drawer
when the vehicle is level. Do not load more weight than the drawer is rated to handle at the proper settings. Do not use the
drawer for any other applications than it is designed for. No one should ever stand or sit on the drawer whether it is in
operation, latched open, or latched shut whether the vehicle is in motion or still. Everyone except the operator should
maintain a safe distance of 4’ while the drawer is being maneuvered to avoid pinch points and shifting. No one should ever be
under the drawer. The vehicle should never be operated unless the drawer is latched securely in its closed position and the
tailgate is secured shut. The drawer should never be used in a vehicle without a tailgate. All loads on top of the drawer
enclosure should be secured down when the vehicle or drawer is in operation. Large loads and heavy loads on top of the
drawer should always be secured to the vehicle; they should not be only secured to the drawer enclosure. Use common sense
when using this product.
WEIGHT RATINGS
LOAD BEARING TOP RATED TO 550#
FULLY EXTENDED WEIGHT RATING FOR EVENLY DISTRIBUTED LOADS (FACTORY SETTING):
PART# 115 = 500#
PART# 109 = 600#
PART# 123 = 700#
THE STOP BOLT CAN BE RE-LOCATED TO LIMIT THE DRAWER EXTENSION TO 75% WHICH WILL INCREASE THE
WEIGHT RATING FOR EVENLY DISTRIBUTED LOADS TO 1500#.
INSTALLATION
1. The drawer assembly comes mounted to a pallet. Pay close attention when removing the drawer from the pallet; it will be
mounted in the vehicle the same way it is mounted to the pallet.
2. First remove all the packaging around the drawer and inspect the drawer assembly for damage.
3. Remove the drawer from the enclosure. To do this unlock the camlock then rotate the handle on the front of the drawer up to
disengage the slide lock assembly. Then pull the drawer out until it hits the stops, lift up on the front end of the drawer to allow
the stop bolt to clear the stop bracket and continue pulling the drawer until it is all the way out. (See Figure 1)
FIGURE 1

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4. Pull the (4) Hairpins out of the Front Mounting Bracket inside the enclosure. Then lift the entire enclosure up off the Front
Mounting Bracket and slide the enclosure forward out of the slot in the rear-mounting bracket then set it aside. (See Figure 2)
WARNING: THE SECOND SLIDE STAGE STILL INSIDE THE ENCLOSURE WILL SLIDE OUT WHEN
MANEUVERING THE ENCLOSURE AND CAN CAUSE INJURY OR DAMAGE. BE SURE TO TAKE PRECAUTIONS
TO AVOID THE SLIDES FROM COMING OUT.
FIGURE 2
5. Remove the (4) Lag bolts holding the Front and Rear Mounting Brackets to the Pallet and set the brackets aside. (See Figure 3)
FIGURE 3

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6. Use the Front and Rear Mounting Brackets as templates. Position them in the truck bed in the correct spots for drilling and mark
the holes with a center punch or marker. Also, check the overall dimension requirements and make sure there is sufficient space
for mounting. (See Figure 4)
Overall dimensions:
Part # 115 - 95 ½” Length, 24 1/8” Wide, 16 ¼” Height
Part # 109 - 71 ½” Length, 24 1/8” Wide, 16 ¼” Height
Part # 123 - 47 ½” Length, 24 1/8” Wide, 16 ¼” Height
FIGURE 4
7. WARNING: Check underneath the truck bed to make sure the frame or a gusset will not interfere with the mounting hole
locations. Also check to make sure there are no hoses, gas tanks, brake lines, mufflers, or other important parts which
could be damaged by drilling. To check these locations measure from a reference point in the truck bed to the marked
holes. Then, using the same reference point on the underside of the bed, measure to locate the marked hole locations on
the under side. If there is interference left to right, use an alternate-mounting hole or drill a new ½” hole in the Mounting
Bracket. If there is interference front to back adjust the overall mounting location or longer grade 8 or alloy mounting
bolts may need to be used to go through a gusset.
8. Drill the (4) marked spots out with a ¼” drill bit first then a ½” drill bit. It is recommended to use silicone sealant in any drilled
holes to prevent future rusting.
9. Fasten the Front and Rear Mounting Brackets to the truck bed. (See Figure 5)

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FIGURE 5
10. Attach the Drawer Enclosure to the truck bed by sliding the rear bolts on the enclosure into the slots on the Rear Mounting
Bracket then drop the front of the Drawer Enclosure onto the pins in the Front Mounting Bracket and insert the (4) Hairpins to
secure it down. (See Figure 6)
11. Check to make sure the Bolts on the rear of the Drawer enclosure are slid completely under the Rear Mounting Bracket. If they
are not, one of the bracket locations will have to be adjusted do remedy the problem. THIS IS A VERY IMPORTANT
SAFETY ISSUE!
12. IMPORTANT: Adjust both bolt stops on the Inside Slide Assemblies to the proper location for weight capacity needs.
(See Figure 6) FIGURE 6

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13. Install the drawer back into the mounting frame assembly in the truck bed. To do this, rotate the Handle up to release the slide
lock assembly. Insert slides. At approximately half way down the front end of the drawer will have to be lifted up so the stop
bolts will clear the stop bracket. (See Fig 7)
FIGURE 7
14. Test slide and slide lock handle operation. When the handle is engaged the drawer should lock into position every 12”. Also,
check the camlock operation.
WARNING: WHEN THE DRAWER IS CLOSED THE SLIDE LOCK MUST BE ENGAGED FOR SAFETY! DO NOT
ONLY USE THE CAMLOCK SYSTEM TO SECURE THE DRAWER SHUT.
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