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Installation Guide for AMP models including: 77138-01A Running Board Assembly, 77138-01A, Running Board Assembly, Board Assembly
Jan 24, 2023 — Ram 1500. Crew Cab 2013-2017. 77138-01A. Ram 2500/3500. Crew Cab 2013-2017. 77138-01A ... follow the instructions below and handle the assembly carefully.
2023-01-24 — Ram 1500. Crew Cab 2013-2017. 77138-01A. Ram 2500/3500. Crew Cab 2013-2017. 77138-01A ... follow the instructions below and handle the assembly carefully.14 puslapių
File Info : application/pdf, 14 Pages, 2.49MB
DocumentDocumentINSTALLATION GUIDE ® APPLICATION TM AMP Part # Ram 1500 Ram 2500/3500 Crew Cab Crew Cab 2013-2017 2013-2017 77138-01A 77138-01A Note:The application works only on the Crew Cab model Vehicles. INSTALLATION TIME 3-5 Hours Professional installation recommended SKILL LEVEL 123 4 4= Experienced TOOLS REQUIRED q Safety goggles q Measuring tape q 10 mm socket q 13 mm socket q 1/2" socket q Ratchet wrench and extension q Wire crimpers q Wire stripper / cutter q 3/16" hex key wrench (allen wrench) q 4mm hex key wrench ( allen wrench ) q Electrical tape q Weather proof caulking (silicone sealer) q Silicone spray WARRANTY 5-Year Limited Warranty AMP RESEARCH TECH SUPPORT 1-888-983-2204 (Press 2) Monday - Friday, 7:00 AM - 5:00 PM PST Invented, engineered and manufactured exclusively by AMP Research in the USA. May be covered by one OR MORE of the following patents: 6,641,158; 6,830,257; 6,834,875; 6,938,909; 7,055,839; 7,380,807; 7,413,204; 7,398,985; 7,584,975; 7,566,064; 7,487,986; 8,157,277; 8,408,571; 9,302,626; 9,561,751; 10,053,017; CA2463717 ©2012 AMP Research. All rights reserved. Printed in USA. www.amp-research.com 1/12 IM77138 rev 01.24.23 AMP RESEARCH POWERSTEPTM Ram Crew Cab INSTALLATION GUIDE Attaching motor to Linkage assembly. EXPLODED VIEW Motor Linkage Motor Kit Delta PT screws CAUTION: HANDLE WITH CARE. To ensure our customers receive all components with full integrity, we pack the motors separate from their linkage assemblies. This requires that the installer position and fasten the motor before continuing with the install. Please follow the instructions below and handle the assembly carefully. CAUTION: Dropping the assembly or any excessive impact MAY cause damage to the motor. Instructions: 1. Position the gear cover in place as shown if not already in place. 2. Seat motor into position on the three mounting bosses. This may require an adjustment of the gear by moving the swing arms. 3. After seating into place, fasten the motor with the three motor mount screws with 4mm Hex Head. Tighten screws to 36 in-lbs (4N-m). Do not over torque. www.amp-research.com 2/12 IM77138 rev 01.24.23 AMP RESEARCH POWERSTEPTM Ram Crew Cab A F (A) End cap left (x1) (B) End cap right (x1) (C) T-nut insert (x2) (D) Socket cap screw (x2) 1 x2 (E) End cap wedge right (x1) (F) End cap wedge left (x1) Running board assembly CE BD 2 x2 Rail Assembly 3 Motor Linkage assembly Driver 4 Motor Linkage assembly Passenger 5 x2 Idler Linkage assembly 6 Wire harness 7 Controller STA www.amp-research.com 8 x2 Posi-LockTM 3/12 9 x16 10 x12 M8 Hex Bolt w Conical washer 5/16-18 Flange Nut IM77138 rev 01.24.23 AMP RESEARCH POWERSTEPTM Ram Crew Cab 11 x6 M5 Hex Bolt 12 x6 M5 Washer 13 x4 14 x4 M6 Flange Bolt 5/16 Flange Bolt 15 x8 Socket Cap Screw 16 x12 5/16-18 Carriage Bolt 17 x8 1/4-20 Flange nut 18 x8 Rivet Nut 19 x8 Button Head Torx Screw 20 x8 Washer 21 x4 Reinforcement Bracket 22 x4 Upper Mount Spacer 23 x4 Blind Rivet 24 x20 Cable tie (7") 25 x2 Cable tie (11") www.amp-research.com 26 x4 LED Lamp 27 x8 Butt Connector 4/12 28 Rivet Nut Tool IM77138 rev 01.24.23 AMP RESEARCH POWERSTEPTM Ram Crew Cab 29 x4 LED Light Bracket 30 OBD II Plug 31 x2 Motor kit 32 Linkage Mounting Bracket Passenger (Front) 33 Linkage Mounting Bracket Driver (Front) 34 Rail Mounting Bracket Passenger (Rear) www.amp-research.com 35 Rail Mounting Bracket Driver (Rear) 5/12 IM77138 rev 01.24.23 AMP RESEARCH POWERSTEPTM Ram Crew Cab HARDWARE MOUNTING OVERVIEW (passenger side shown) Locate forward most and rearward most mounting provisions on inner sill of truck. Remove tape from sill drain hole at both mounting points. Note: Some vehicles may have Front welded fastners installed already. Backing plates and rivet nuts are not needed on these locations. Factory Rivet nuts will need to be removed to install backing plates. 1 Driving Assembly Front Idler Assembly NOTE: Driving Linkage Assemblies (with motor) mount in the front; Idler Assemblies mount in the rear. Set Reinforcement Plate in place and locate with rivet nuts. Drill hole using an 1/8" drill bit. After drilling apply paint to prevent rusting Once hole is drilled insert a piece of string or wire through hole in Reinforcement Plate. Set plate into position. 2 Set rivet nuts into place for alignment. Insert pop rivet through hole in plate and secure in place. Once pop rivet is installed remove string or wire from Reinforcement Plate. NOTE: Verify plate is pulled flush to the body before securing pop rivet. Assemble Hex Bolt (lubricated with soapy water), Washer, Rivet Tool, and Rivet Nut together as shown and place into hex cutouts in sill. An extra Hex Bolt and M8 Washer is supplied to install rivet nuts. 3 www.amp-research.com 4 6/12 IM77138 rev 01.24.23 AMP RESEARCH POWERSTEPTM Ram Crew Cab With Rivet Nut Tool held in place with 19mm wrench, tighten Hex Bolt until Rivet Nut deforms and secures itself to the sheet metal (110 in-Lbs. or 4 turns). Remove Hex Bolt and Rivet Nut Tool. Repeat for each of the four mentioned mounting locations. Once rivet nuts are in place use a screwdriver to push back tab in hole to avoid interference with linkage mount. WARNING: Rivet Nuts not properly collapsed will not hold securely to sheet metal. NOTE: Hold Rivet tool with 5 wrench while loosening bolt. 6 On Passenger side install Rear Rail Mounting Bracket (34) and Front Linkage Mounting Bracket (32) using the Hardware provided. 4 Conical washer bolts (9), 4 Button Head Torx (19), washers (20) and Flange Nuts (17). Once bolts are tightened up to vehicle torque Conical washer bolts (9) to 16 ft-lbs and Button head Torx to 6ft-lbs. Repeat on Driver side using rear bracket (35) and front bracket (33). 9 9 7 17,19&20 17,19&20 Insert and position 6 Carriage bolts (16) into slot on rail (4). Insert from either end of rail. Using Flange Nuts (10) provided assemble rail to Brackets using the 2 outer bolts on each side. Next install Flange Bolt (14) and Flange Nut (10) onto bracket tab. Torque flange nuts to 16ft-lbs. Install Light Bracket (29) using Flange Nut (10), leave loose to allow for adjustment. Driver side shown. Dimensions shown are for reference. 16 29 1106 1143 10 1106 & 176 Note: Badge on rail sits towards the rear of the vehicle! 8 www.amp-research.com 7/12 106 & 1176 IM77138 rev 01.24.23 AMP RESEARCH POWERSTEPTM Ram Crew Cab Thread supplied bolts 2x (9) into Front Drive Linkage. Repeat step for Rear Idler Linkage. Do not tighten. Install provided spacer (22) and M6 bolt (13) into upper mount as shown on both the Drive and Idler linkages. Do not tighten. 13 22 98 8 19 14 91 Slide mounting T-nut into position, Center board in rail pocket. Tighten fasteners to 10 ft-lbs. 9 10 Using a 13mm socket Torque linkage bolts 4x (9) from step 3 to 16 ft-lbs. Next use a 10mm socket, torque linkage spacer bolt 2x (13) from step 6 to 8 ft-lbs. Once linkages are tight cycle board to verify steps deploy under own weight. 143 2129 11 Once linkages are tightened to the bracket tighten bracket tab Flange bolt (14) and Nut (17). Torque to 16 ft-Lbs. 12 8 Attach motor to linkage. Using a 4mm hex Torque to 36 in-Lbs. 167 143 153 www.amp-research.com 114 8/12 IM77138 rev 01.24.23 AMP RESEARCH POWERSTEPTM Ram Crew Cab Prepare large tie-wraps (25) for mounting Power Step Controller (7). Loosely loop tie-wraps around large bundle of wires behind battery in engine compartment. Insert controller (7) into tie-wrap loops and cinch down securely. The tie-wraps (25) should cinch down into channels on controller surface. 26 7 115 Remove fuse from Power Step Wire Harness. 16 Connect power leads from Controller, Red to positive battery terminal and Black to the vehicle body ground as shown. 6 6 17 158 Locate large rubber wire boot on driver side firewall as shown below. Slice small opening as shown below to run trigger wires through. Tape leading end of wires together and push through rubber boot to cabin side of the firewall. Silicon lubricant may be used for ease of passage. The trigger wires will come out just above and to the left of the brake pedal. 159 www.amp-research.com 250 9/12 IM77138 rev 01.24.23 AMP RESEARCH POWERSTEPTM Ram Crew Cab Route the two Wire Harness legs down over the wheel wells toward Motor Linkages, long leg across to the passenger side. Secure harness with tie wraps. Connect harness to motor. Secure harness with tie wraps. 4 211 22 Affix LED lamp (26) to Light bracket (29) on rail. Slide bracket into desired position and tighten using 5/32" Allen key. 23 5 Using supplied butt connectors (27), connect the lamp wires. Red to Red, Black to Black. Once Crimped use heat gun to shrink tube. Close and wrap conduit with electrical tape. Secure all loose wires with cable ties. Pull lamp wires upward to avoid any wire snagging. 254 www.amp-research.com 10/12 IM77138 rev 01.24.23 AMP RESEARCH POWERSTEPTM Ram Crew Cab OBD II install: Use Supplied Posi Twist connectors to attach the Plug and Play Module to the Harness. Attach matching colors on the harness to the wires on the module. Plug in module to OBD II port on the vehicle. Secure harness with supplied tie wraps. Note: If the OBD II pass thru harness (76404-01A) was purchased see install sheet supplied in packaging. The pass through harness allows for an open port for other accessories. See next page for a brief description. OBD II Connector located below steering column. To Powerstep Motors To Vehicle Power (12V) Powerstep Control Module Vehicle Port Powerstep Connection Module Direct to Port Option To Vehicle Power (12V) To Powerstep Motors 25 www.amp-research.com Powerstep Connection Module Powerstep Control Module Vehicle Port Pass-Through Harness Option Vehicle Port Pass-Through Harness (pin-topin at each terminal) New Vehicle Port (replaces original port) 11/12 IM77138 rev 01.24.23 AAMMPP RREESSEEAARRCCHH PPOOWWEERRSSTTEEPPTTMM RRaamm CCrreeww CCaabb Check that all doors activate the Power Step and the LED Lights work when doors open and close. Reinstall any remaining trim panels. FINAL SYSTEM CHECK Check that all doors activate the PowerStep and the LED lights work when doors open and close. NORMAL OPERATION: When the doors open, PowerStep automatically deploys from under the vehicle. When the doors are closed, PowerStep will automatically return to the stowed/retracted position. Note that there is a 2-second delay before the PowerStep returns to the stowed/retracted position. CORRECT OPERATION OF LIGHTS: All four lamps will illuminate upon opening any door of vehicle. Lamps will stay on until restowing of both Power Steps or until 5 minutes has expired with the doors open. When the lights timeout after 5 minutes, they can be reillumintated by closing and opening any door of vehicle. 3276 www.amp-research.com 12/12 IM77138 rev 01.24.23 TM AMERICAN DESIGNED, ENGINEERED AND MANUFACTURED. Thank you for your recent AMP Research Purchase. REGISTER YOUR PRODUCT TODAY FOR FASTER SERVICE & PRODUCT UPDATES Please visit: www.amp-research.com/productregistration or scan the QR Code Product Registration Benefits: · Ensure we have your purchase receipt and product info in our system which is required for warranty · Faster and easier access to customer service and tech support in the unlikely event you need warranty or product support · Registration helps us keep you up to date on product information and offers To view other Amp Research products that may be offered for your vehicle. Please visit: www.amp-research.com Rev 01.05.21 TM Congratulations on your purchase of the genuine AMP Research PowerStep! Here's what you should know... AMP Research PowerStep running boards automatically move when the doors are opened to assist entering and exiting the vehicle. Automatic power deploy: The running boards will extend down and out when the doors are opened. Automatic power stow: The running boards will return to the stowed position when the doors are closed. There will be a 2-second delay before the running boards move to the stowed position. Automatic stop: If an object is in the way of the moving running board, the running board will automatically stop. To reset, clear any obstruction, then simply open and close the door to resume normal operation. Manually set in the deployed (OUT) position for access to the roof: your foot while at the same time closing the door. To resume normal operation, open and close the door. Maintenance: In adverse conditions, debris such as mud, dirt, and salt may become trapped in the running board mechanism, possibly leading to unwanted noise. If this occurs, manually set the running boards to Avoid spraying the motors directly. After washing, apply silicone spray lubricant to the hinge pivot pins. Do not apply silicone, wax or protectants like Armor All® to the running board stepping surface. Caution! Keep hands away when the running board is in motion. 5-YEAR LIMITED WARRANTY AMP RESEARCH warrants this product to be free from defects in material and workmanship for FIVE (5) YEARS FROM DATE OF PURCHASE, provided there has been normal use and proper maintenance. This warranty applies to the original purchaser only. All remedies under this warranty are limited to the repair replacement of the product itself, or the repair or replacement of any component part thereof, found by the factory to be defective within the time period specified. The decision to repair or replace is wholly within the discretion of the manufacturer. for instructions. You must retain proof of purchase and submit a copy with any items returned for warranty work. Upon completion of warranty work, if any, we will return the repaired or replaced item or items to you freight prepaid. Damage to our products caused by accidents, fire, vandalism, negligence, misinstallation, misuse, Acts of God, or by defective parts not manufactured by us, is not covered under this warranty. ANY IMPLIED WARRANTIES OF MERCHANTABILITY AND/OR FITNESS FOR A PARTICULAR PURPOSE CREATED HEREBY ARE LIMITED IN DURATION TO THE SAME DURATION AND SCOPE AS THE EXPRESS WRITTEN WARRANTY. OUR COMPANY SHALL NOT BE LIABLE FOR ANY INCIDENTAL OR CONSEQUENTIAL DAMAGE. Some states do not allow limitations on how long an implied warranty lasts, or the exclusion or limitation of incidental or consequential damages, so the above limitations or exclusions may not apply to you. This warranty gives you specific legal rights, and you may also have other rights that vary from state to state. FOR WARRANTY ISSUES WITH THIS PRODUCT PLEASE CALL AMP RESEARCH TECH SUPPORT 1-888-983-2204 WARNING Be sure to read and precisely follow the provided instructions when installing this product. Failure to do so could place the vehicle occupants in a potentially dangerous situation. After installing or reinstalling, re-check to insure that the product is properly installed. The material that your product is made from can be recycled. Please also consider recycling the packaging that your product came in.