Tommy Gate 1000 Series Quick Start Manual

CYLINDER REPAIR/REPLACEMENT - 1000-1600 LB
NOTICE: Tommy Gate ISO Grade 32 hydraulic fluid or ISO Grade 32 equivalent is recommended. See page 4 for more details.
Preparing the Gate
1. PARK the vehicle on a level surface and set the parking brake.
Note: Keep body parts clear of moving parts during liftgate operation.
2. REMOVE the box cover fasteners (Figure 1).
3. REMOVE the box cover.
4. ACTIVATE the control.
A) Push the hidden "POWER ON" switch. The amber "POWER ON" LED will illuminate.
B) Push the hidden "LIFTGATE ACTIVATED" switch twice within one (1) second.
The red "LIFTGATE ACTIVATED" LED will illuminate. With both lights on, the
liftgate can be raised or lowered. If not used for 90 seconds, the control will
automatically shut off .
5. LOWER the liftgate until the arms are parallel with the truck bed (Figure 1)
The arms must be parallel with the truck bed to remove the master link.
6. BLOCK the liftgate under the false floor.
7. PUSH down on the toggle switch until all the pressure in the hydraulic
system is relieved.
8. DISCONNECT the 4ga ground cable from the battery, if previously installed.
9. DISCONNECT the 4ga power cable from the battery, or manually TRIP the circuit breaker.
10. REMOVE the three screws holding the control to the upright, (recessed controls only).
11. REMOVE the control from the upright and allow it to hang by the control wire (recessed controls only).
Removing the Cylinder
1. DISCONNECT the hydraulic hose from the tee on the power unit housing (Figure 2).
A) Place a rag underneath the tee to absorb any hydraulic oil that leaks when hose is loosened.
WARNING:
If the following steps are not performed, warranty will not be awarded for pulled threads.
B) Loosen the tee jam nut. While attempting to loosen the jam nut with an open end
wrench, hold the tee in place using another open end wrench.
C) Loosen the hose connected to the tee. While attempting to loosen the hose with an
open end wrench, hold the tee in place with another open end wrench.
D) Place the end of the disconnected hose over a bucket to drain the remaining hydraulic
fluid from the cylinder.
2. REMOVE the master link assembly (Figure 3).
Note: New snap rings and shim(s) for the master link are provided in the kit.
A) Remove the two snap rings from the master link assembly.
B) Remove the master link side plate.
C) Remove the shim.
D) Remove the master link.
3. REMOVE the upright cap screw(s) or unscrewing snap rivets from the uprights (Figure 4).
4. REMOVE the upright cap (Figure 4). Upright cap design may vary.
5. REMOVE the cylinder pin (Figure 4).
A) Remove the snap ring from the cylinder pin.
B) Remove the pin keeper screw.
C) Remove the cylinder pin.
Note: Sketch or photograph how the hose is routed as this is how you will route the hose later.
6. REMOVE the cylinder and hydraulic hose by pulling them out the top of the upright.
7. REMOVE the hose from the cylinder (only if replacing the complete cylinder) (Figure 5).
A) Hold the flow control in place with an open end wrench.
B) Loosen the hose with another open end wrench.
8. VERIFY that the hose and O-ring are in good condition and free of cuts or wear marks (Figure 5).
If the hose and O-ring are in good condition proceed to the next step. If not call Tommy Gate.
Hydraulic cylinder
DPN: 095007
Check O-ring condition
Hold with open end wrench
Figure 5: Hydraulic hose and cylinder.
R
SERIES
Snap Ring
Loosen with open end wrench
Hydraulic hose
Page 1 of 4
Box
Cover
False
Floor
Figure 1: Box cover and fasteners.
Hydraulic hose
Figure 2: Hydraulic hose and Tee.
Master Link
Side Plate
Shim
(use with 7ga guide plate only)
Figure 3: Master link assembly.
Unscrewing
Snap Rivet
Screw(s)
Cylinder Pin
Pin Keeper
Screw
Cylinder
Figure 4: Upright cap and cylinder pin.
Rev 7
Box
Cover
Fasteners
Arms Parallel
with Truck Bed
Tee
Jam
Nut
Guide
Ram Adjuster
Master
Link
Thin Shim
Upright Cap
(design varies)
Snap
Ring
Upright
6-11-21