7.
Step 9 If possible, install diagonal braces from the lower part of the rails to the vehicle body
(see Figure 9). On lower bed heights, the rails may need trimmed to maintain an ad-
equate 18" of ground clearance. NEVER trim the rails more than 22" from the ground
OR so high that lower nylon wear pads drop, EVEN PARTIALLY, out of rails, which may
cause liftgate to jam up or cause damage to liftgate (see Figure 9). This 22" maximum
dimension MUST be measured on an unloaded truck, or this dimension will be ex-
ceeded when the truck is unloaded. (On special orders, consult factory as the allow-
able trim dimensions may vary from what is shown here).
Step 10 Fasten the 150 AMP circuit breaker provided within 2 ft. of the truck battery. Route
battery cable from the pump enclosure toward the 150 AMP breaker. AVOID SHARP
CORNERS AND HIGH HEAT AREAS! Use cable clips provided to secure the cable
to the truck frame every 2 feet. Cut the cable to the desired length and strip .75"
of insulation from the end. Slide the pre-cut heat shrink over the end of the cable.
Secure the cable lug in a vise and apply heat to the connector and insert the cable as
the solder melts. Allow connector to cool and install the heat shrink. Attach this end
to one terminal on the 150 amp breaker. Wire the breaker to the truck battery using
the 2 ft. cable provided. Bolt the grounding cable from the liftgate to the truck frame.
See figure 10.
Step 11 Many late model trucks have battery connections as shown in figure 10. The ground
cable from the battery may be run directly to the engine block with only a light
braided ground strap connecting the block to the chassis. Where this is the case, the
factory installed cable usually does not provide an adequate ground circuit for oper-
ating battery powered liftgates. We recommend that the cables labeled with an “X”
be not less than #2 gauge cable as supplied in the installation kit. Also, due to the
high current draw (Approx. 200A) we recommend that the alternator be a heavy duty
type and the battery must have a 150 AMP minimum reserve capacity.
Step 12 The TVL above bed models are pre-set to travel 10 inches above bed. Depending on
the bed height it may be possible to obtain up to 16 inches above bed. Refer to table
1. To do this some of the lift chain must be removed. This amount is the same as the
additional travel desired. The platform must be completely lowered to the ground and
the cylinder housing cover removed. Remove the jam nuts and tension rods attached
to the chain and cut off the required amount from each chain. Push the cylinder rod
in and re-assemble the tension rods and replace cover. Raise the platform and check
dimensions and adjust as necessary.
Step 13 Platform manual closing torsion assist is preset at the factory, however, if it is neces-
sary to adjust the closing torsion, use the following steps to do so: (See figure 12).
A. Place the platform in the stowed (vertical) position making sure the platform stow
bars are secured in the resting place on both sides of the liftgate.
B. Remove the .62" diameter retention bolt (A) from the center of the tension adjust-
ing bracket.
C. Place a .50" square breaker bar in the square hole of the tension adjusting
bracket.
D. Turn breaker bar counterclockwise to relieve the force on the .38" diameter bolt
(B) and remove bolt (B) noting the position of the tension adjusting bracket at the
initial setting.
Summary of Contents for NTEA TVL Series
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