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Installation Guide for AMP RESEARCH models including: 77240-01A Running Board Assembly, 77240-01A, Running Board Assembly, Board Assembly
File Info : application/pdf, 14 Pages, 2.02MB
DocumentDocumentINSTALLATION GUIDE APPLICATION Ram 1500 ® Crew Cab 2019 - 2022 TM AMP Part # 77240-01A 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 IM77240 rev 04.08.22 AMP RESEARCH POWERSTEPTM Ram Crew Cab EXPLODED VIEW · Motor · Socket cap screw · Washer · Drive Gear Housing Cover 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 IM77240 rev 04.08.22 AMP RESEARCH POWERSTEPTM Ram Crew Cab A F Cut Dimension 1 x2 (A) End cap left (x1) (B) End cap right (x1) (C) T-nut insert (x2) (D) Socket cap screw (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 Passenger 4 Motor Linkage assembly Driver 5 x2 Idler Linkage assembly 6 Wire harness www.amp-research.com 7 Controller STA 3/12 8 x2 Posi-LockTM 9 OBD II Plug IM77240 rev 04.08.22 AMP RESEARCH POWERSTEPTM Ram Crew Cab 10 x6 M5 Washer 11 x4 12 x4 M6 Flange Bolt 5/16 Flange Bolt 13 x8 Socket Cap Screw 14 x12 5/16-18 Carriage Bolt 15 x8 M8 Hex Bolt w Conical washer 16 x16 5/16-18 Flange Nut 17 x6 M5 Socket Cap Screw 18 x12 Nut with Conical Washer 19 x4 Upper Mount Spacer www.amp-research.com 20 x20 Cable tie (7") 21 x2 Cable tie (11") 4/12 22 x8 Butt Connector IM77240 rev 04.08.22 AMP RESEARCH POWERSTEPTM Ram Crew Cab 23 x4 LED Lamp 24 x4 LED Light Bracket 25 x2 Gear Cover 26 x2 Motor 27 x2 Linkage Mounting Bracket Driver www.amp-research.com 28 x2 Linkage Mounting Bracket Passenger 5/12 IM77240 rev 04.08.22 AMP RESEARCH POWERSTEPTM Ram Crew Cab Insert and position 6 Carriage bolts (14) into slot on rail (2). Insert from either end of rail. Using Flange Nuts (16) provided assemble Brackets (27 & 28) onto the rail (2) using the 2 outer bolts for each bracket.Next install Light Bracket (24) using Flange Nut (10), leave loose to allow for adjustment. Driver side shown. Dimensions shown are for reference. Do not tighten this will allow for rail adjustment when mounted onto vehicle. TRX Models 7.2 All other Models 8.75 14 16 24 51.50 Distance 1 Rear of Vehicle Note: Badge on rail sits towards the rear of the vehicle! Front of Vehicle Install Flange head bolt (12) and Flange Nut (16) onto bracket tab as shown. Do not torque to allow for future adjustments. Set rail up into position. Starting with the rear bracket work towards the front bracket. Slide Brackets over captive studs and use provided Nuts 6x (18). Snug to body and torque to 16 ft-lbs. 2 Thread supplied bolts 2x (15) into Front Drive Linkage. Repeat step for Rear Idler Linkage. Do not tighten. 185 19 14 3 Install provided spacer (19) and M6 bolt (11) into upper mount as shown on both the Drive and Idler linkages. Do not tighten. 19 11 4 www.amp-research.com 5 6/12 IM77240 rev 04.08.22 AMP RESEARCH POWERSTEPTM Ram Crew Cab Slide mounting T-nut into position, Center board in rail pocket. Tighten fasteners to 10 ft-lbs. Using a 13mm socket, torque linkage bolts 4x (15) from step 4 to 16 ft-lbs. Next use a 10mm socket, torque linkage spacer bolt 2x (11) from step 5 to 8 ft-lbs. Once linkages are tight cycle board to verify steps deploy under own weight. 1141 1199 16 Once linkages are tightened to the bracket tighten bracket tab Flange bolt (12) and Nut (16). Torque to 16 ft-Lbs. 7 185 Attach motor to linkage. See page 2 for torque specs. 8 91 Attach wire harness to controller (make sure connector locking tabs fully engage). Mount controller with the two 11" tie wraps to factory conduit, just rearward of battery. Remove fuses from Power Step Wire Harness. 6 150 www.amp-research.com 7/12 IM77240 rev 04.08.22 AMP RESEARCH POWERSTEPTM Ram Crew Cab Connect red power lead to battery. Connect black ground lead to 13mm bolt outside of fender wall. Black ground lead wire. Secure with cable ties. 111 Route shorter leg of harness down Driverside wheel well and longer leg of harness across firewall and down along passenger side wheel well. Attach wire harnes with supplied 7" cable ties (20). 12 Locate rubber boot to the left of the steering column. Poke hole to fish trigger wires thru. 153 www.amp-research.com 8/12 IM77240 rev 04.08.22 AMP RESEARCH POWERSTEPTM Ram Crew Cab Plug OBD (9) to port, tuck wires up and away to prevent snagging when entering and exiting the vehicle. Locate side access cover of dash and remove to gain better access to 2 pin plug for OBD harness installation. 14 15 Locate green plug. And plug 2 pin connector from module into this port. Note: It's best to reach from both sides when installing 2 pin plug. Any open port on 156 green plug can be used. www.amp-research.com 9/12 IM77240 rev 04.08.22 AMP RESEARCH POWERSTEPTM Ram Crew Cab OBD II install: Use Supplied Posi-Lock® connectors (8) 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 1272 www.amp-research.com 18 Powerstep Connection Module Powerstep Control Module Vehicle Port Pass-Through Harness Option 19 Vehicle Port Pass-Through Harness (pin-topin at each terminal) New Vehicle Port (replaces original port) 10/12 IM77240 rev 04.08.22 AMP RESEARCH POWERSTEPTM Ram Crew Cab On driver side, run Wire Harness leg down and along underside of the vehicle floor and frame to front Drive Linkage. Connect harness to motor and secure harness with tie wraps. Route remainder of wire harness towards rear linkage assembly for LED lights. On Passenger Side, run Wire Harness leg down and along underside of the vehicle floor and frame to front Drive Linkage. Connect harness to motor and secure harness with tie wraps. Route remainder of wire harness towards rear linkage assembly for LED lights. 6 118 19 Affix LED lamp (23) to LED Bracket (24) as shown. Affix LED light bracket assembly to rail. Mount front light rearward of front linkage and mount rear light just forward of rear linkage. 20 Using supplied butt connectors (22) 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. 251 www.amp-research.com 11/12 IM77240 rev 04.08.22 AAMMPP RREESSEEAARRCCHH PPOOWWEERRSSTTEEPPTTMM RRaamm CCrreeww CCaabb Reinstall Fuses and check that all doors activate the Power Step and the LED Lights work when doors open and close. Reinstall any remaining trim panels. 6 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. 3272 www.amp-research.com 12/12 IM77240 rev 04.08.22 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.