TITAN 200 Series, PU-200 Manual

ASSEMBLY INSTRUCTIONS

PU-200

1. Remove the tailgate and the license plate from the truck. Newer trucks may require you to disconnect wiring for backup camera/ tailgate light.
   
2. Place strut channel nut into stake pocket bracket. The strut channel nut should be inserted so it will correspond with the mounting hole inside the bed.
   
   **Some trucks may require a hole to be drilled inside the bed. *
   
3. Place stake pocket brackets into truck stake pockets. Stake pocket adjustment slots should sit perpendicular with bed rails. Secure each with ⅜" x 1½" flange bolt and stake pocket washer. (Install provided blue thread sealer on bolt threads).
   
4. Prep storage self for installation by placing (16) extruded u nuts over predrilled holes.
   
5. Place storage shelf inside 24" front rack assembly, line up holes and insert (16) stainless ¼" screws with a Phillips screwdriver. A screwdriver can be helpful to get holes aligned properly.
   
6. Place assembled 24" front storage rack assembly onto front stake pockets. Place (4) ⅜" x ¾" carriage bolts & (4) ⅜" flange nuts in each stake pocket.
   
   Only hand tighten these bolts for now. (Install provided blue thread locker on bolt threads)
   
7. Insert side rails by sliding them into the front rack assembly. You may need to loosen the set bolt near the end of the tube (9 /16'' wrench). Do not tighten the set bolt yet.
   
8. Secure side rails to back stake pocket brackets with (4) ⅜" x ¾" carriage bolts and (4) ⅜" flange nuts.
   
   Only hand tighten these bolts for now. (Install provided blue thread sealer on bolt threads)
   
9. Insert adjustable hitch. This is made to fit a 2" receiver hitch. Remove the license plate from the truck. This will be installed on the ramp during a later step.
   **Some trucks may require a sleeve spacer. **
   
10. Remove the ramp pin from the tube of the dovetail.
    
11. Sit the dovetail on its side (gate brackets down) and install adjustable hitch a frame with (6) ⅜" x ¾" carriage bolts and (6) ⅜" flange nuts. This should be installed in the most forward position.
    
12. SEE "ASSEMBLY INSTRUCTIONS - QD-100" FOR QUICK DISCONNECT INSTALLATION. Once that is complete, please continue to the next step.
13. Install wiring harness. Thread harness through pre notched holes in bottom of dovetail. Use provided zip ties and secure along the dovetail rib.
    
14. Remove rubber grommet from ¾" marker light. Insert marker light through mounting hole. Re-install rubber grommet into the pre-drilled mounting hole in metal. Install marking light into grommet and press into place.
    
15. Install 6" oval rubber grommet into precut hole for taillight. Pull the taillight plug through the hole where the rubber grommet was installed, connect wiring, and press into place.
    
16. Lift dovetail unit and hook over side rails. Place pin in adjustable hitch sleeve. Insert (2) ⅜" x 2½" flange bolts and (2) ⅜" flange nuts.
    **Three people are recommended for this step**
    
17. Slide the unit forward as needed to fill the gap if needed. Lift and adjust the pins in the adjustable hitch and the adjustable hitch a-frame insert as needed to ensure dovetail is level.
    
18. Attach ramp to dovetail with ramp pin. Once ramp pin is in place secure with (1) ⅜" x ¾" flange bolt and (1) ⅜" flange nut.
    **Three people are recommended for this step**
    
19. While the ramp is in the down position, install gate spring latches. Secure with (2) ¼" x 1¼" bolts and (2) ¼" lock nuts on each side.
    
20. Lift the ramp into the upright position and attach a lift assist gate spring with (2) quick links. It is IMPORTANT to install safety cable in case of spring failure.
    
21. Place (4) extruded U nuts over predrilled holes in the license plate bracket. Secure tag with (4) ¼" stainless screws.
    
22. Connect taillight into harness & connect the wiring harness to 4 flat trailers plug or 7 pin adapters.

NOTICE
YOU ARE RESPONSIBLE TO ENSURE THIS PRODUCT COMPLIES WITH YOUR STATE AND LOCAL LAWS AND REGULATIONS.
THE RAMP PORTION OF THIS UNIT HAS BEEN ENGINEERED TO SUPPORT 2000LBS. DO NOT EXCEED THIS WEIGHT LIMIT.
IT IS YOUR RESPONSIBILITY TO ENSURE YOU DO NOT OVERLOAD YOUR VEHICLE; SPECIFICALLY THE REAR GROSS VEHICLE WEIGHT RATING (RGVWR) THIS CAN BE FOUND ON THE INSIDE OF THE DRIVERS DOOR.

PARTS GUIDE

QD-100

1. Insert the custom jack into the adjustable hitch "A" frame and secure with jack mounting bracket and (2) ⅜" x 1½" carriage bolts and (2) ⅜" flange nuts. Ensure this is tightened down well to prevent your jack from slipping.
   
2. Attach the jack handle plate to the side of dovetail and secure with (2) ⅜" X ¾" bolts and (2) ⅜" flange nuts.
   
3. Insert jack handle extension through the jack handle plate and onto the jack. Secure with (1) ¼" x 1¼" bolt and (1) ¼" lock nut through the pre-drilled hole. A hammer can be helpful to get the jack handle extension onto the jack. The handle should be straight. If it is angled, adjust the position of the jack handle plate.
   
4. Attach a turnbuckle to each side of the dovetail using (2) 5 /16" lynch pins on each.
   
5. Remove the ⅜" x 2½" flange bolts on the dovetail and replace with the hitch pins w/chain.

PARTS DIAGRAM/EXPLODED VIEW

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