JY PERFORMANCE DAC791 Dual-Side Trailer Tailgate Lift Assist System

1. Introduction

This manual provides comprehensive instructions for the installation, operation, and maintenance of the JY PERFORMANCE DAC791 Dual-Side Trailer Tailgate Lift Assist System. This system is designed to significantly reduce the effort required to lift and lower trailer tailgates and ramps, promoting safer operation and extending the lifespan of your trailer gate by preventing uneven stress and wear.

Please read this manual thoroughly before installation and use to ensure proper function and safety.

2. Product Overview

The JY PERFORMANCE DAC791 is a dual-side lift assist system engineered for utility trailers. Its design ensures balanced lifting, which is crucial for the longevity and stability of your trailer's tailgate or ramp.

Figure 2.1: JY PERFORMANCE DAC791 Dual-Side Trailer Tailgate Lift Assist System installed on a utility trailer.

Key Features:

• Dual-Side Assist: Prevents uneven tension and wear on the tailgate/ramp and trailer, extending its service life.
• Wide Compatibility: Designed for most open utility trailers with 12-24 inch (30.5-61 cm) side rails and tailgates or ramps measuring 4-6 feet (1.2-1.8 m) in height.
• Effortless Lifting: After installation, the tailgate becomes significantly lighter, allowing for easy manual lifting.
• Durable Construction: Made from heavy-duty, powder-coated alloy steel for strength and corrosion resistance.
• High Load Capacity: Supports tailgates with a load capacity of up to 136 kg (300 lbs).

Figure 2.2: Dual-Side Lift Assist Design for enhanced longevity, stability, and balance.

Figure 2.3: Detailed view of the lift assist system components.

3. Compatibility

This lift assist system is compatible with most open utility trailers that meet the following criteria:

• Side Rail Height: 12 inches (30.5 cm) to 24 inches (61 cm)
• Tailgate or Ramp Height: 4 feet (1.2 m) to 6 feet (1.8 m)

Figure 3.1: Compatibility diagram for utility trailers, showing required side rail and tailgate dimensions.

The system is ideal for utility, landscape, and cargo trailers with heavy tailgates.

Figure 3.2: Examples of trailers compatible with the lift assist system.

4. Installation

4.1 Included Components

The package includes the following components:

• Lift Assist Mechanisms (2 units)
• 150 cm (59 inch) Cable
• Mounting Hardware (bolts, nuts, washers, brackets)
• Installation Instructions

Note: While mounting hardware is included, some trailer designs may require additional or specific hardware not supplied. Ensure all hardware is suitable for your trailer's construction (e.g., metal vs. wood).

4.2 Tools Required

• Drill
• Drill bits appropriate for your trailer material (metal or wood)
• Wrenches or sockets
• Measuring tape
• Marking tool
• Safety glasses and gloves

4.3 Installation Steps

Important: Drilling is required for installation. Always ensure the trailer is stable and secure before beginning installation. Wear appropriate safety gear.

1. Position the Lift Assist Mechanism: Determine the optimal mounting location on your trailer's side rails, ensuring it aligns with the tailgate's pivot points. Refer to the included detailed installation instructions for specific measurements and placement guidelines.
2. Mark Drilling Points: Use a marking tool to accurately mark the locations for drilling holes based on the mounting brackets.
3. Drill Holes: Carefully drill the marked holes. Ensure the drill bit size matches the provided hardware.
4. Attach Brackets: Securely attach the mounting brackets to the trailer using the provided bolts, nuts, and washers.
5. Install Lift Assist Units: Mount the lift assist mechanisms onto the installed brackets.
6. Connect Cable: Route and connect the 150 cm cable according to the instructions, ensuring it is properly tensioned. The cable connects the lift assist mechanism to the tailgate.
7. Test Operation: After installation, slowly raise and lower the tailgate to ensure smooth operation and proper function of the lift assist system. The tailgate should feel significantly lighter.

For visual guidance, refer to the detailed installation diagrams provided in the separate instruction sheet included with your product.

5. Operation

The JY PERFORMANCE DAC791 system is designed for straightforward operation once installed.

5.1 Lifting the Tailgate

• Grasp the tailgate firmly.
• Apply upward pressure. The lift assist system will engage, making the tailgate feel nearly weightless and easy to lift into its closed position.

5.2 Lowering the Tailgate

• Release any latches securing the tailgate.
• Grasp the tailgate firmly and guide it downwards. The lift assist system will provide controlled resistance, preventing the tailgate from dropping suddenly.

Figure 5.1: Demonstration of effortless tailgate lifting after system installation.

6. Maintenance

Regular maintenance ensures the longevity and optimal performance of your lift assist system.

• Inspection: Periodically inspect all components, including cables, springs, brackets, and mounting hardware, for signs of wear, damage, or corrosion.
• Lubrication: Apply a suitable lubricant to moving parts, such as pivot points and spring mechanisms, as needed to ensure smooth operation.
• Cleaning: Clean the system components regularly to remove dirt, debris, and road grime. The powder-coated finish is designed for durability, but keeping it clean will help prevent premature wear.
• Hardware Check: Ensure all bolts and nuts remain tight. Re-tighten if any looseness is detected.
• Cable Condition: Check the cable for fraying or kinks. Replace immediately if any damage is observed.

7. Troubleshooting

If you encounter issues with your lift assist system, consider the following common solutions:

• Tailgate is still heavy:
  • Verify that the system is correctly installed and tensioned according to the instructions.
  • Ensure the tailgate weight does not exceed the system's 136 kg (300 lbs) capacity.
• Uneven lifting:
  • Check both lift assist units for proper installation and function.
  • Inspect cables and springs for damage or improper routing.
• Squeaking or grinding noises:
  • Lubricate all moving parts.
  • Inspect for any obstructions or misaligned components.
• Loose components:
  • Periodically check and tighten all mounting hardware.

If problems persist after attempting these solutions, contact customer support for further assistance.

8. Specifications

Figure 8.1: Load capacity and material details.

9. Customer Support

For technical assistance, warranty inquiries, or replacement parts, please contact JY PERFORMANCE customer support. Refer to your product packaging or the retailer's website for the most current contact information.

Please have your model number (DAC791) and purchase date available when contacting support.