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Installation Guide for AMP RESEARCH models including: 76140-01A Running Board Assembly, 76140-01A, Running Board Assembly, Board Assembly, Assembly
File Info : application/pdf, 17 Pages, 1.89MB
DocumentDocumentINSTALLATION GUIDE TM APPLICATION Ford Ranger - Super Crew Ford Ranger - Super Cab Ford Bronco - 4 Door Ford Bronco - 2 Door ® LENGTH 72" 65" 72" 55" MODEL YR 2019 - 2021 2019 - 2021 2021 2021 PART # 76140-01A 76140-01A 76140-01A 76140-01A 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 10 mm ratchet wrench q 13 mm ratchet wrench q 15 mm ratchet wrench q Ratchet wrench and extension q Pliers q Wire crimpers q Wire stripper / cutter q 3/16" H ex key wrench (allen wrench) q Electrical tape q Weather proof caulking (silicone sealer) q 1/8" Drill bit q 9/32" Drill bit q Drill q Heat Gun q 6" Extension 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 1/15 IM76140 rev 01.14.22 AMP RESEARCH POWERSTEPTM FORD RANGER / BRONCO INSTALLATION GUIDE Attaching motor to Linkage assembly The motors must be attached to the Linkage assemblies on step 5 EXPLODED VIEW · Motor · Socket cap screw · Motor Linkage assembly · Cinch Fastners 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 2/15 IM76140 rev 01.14.22 AMP RESEARCH POWERSTEPTM FORD RANGER / BRONCO Note: Some Applications require modification. Application Ranger Crew Cab, Bronco 4 Door Extended Cab Bronco 2 Door Cut Length 72" (No Modification Required) 65" (Trim 7") 55" (Trim 17") COMPONENT/PARTS IDENTIFICATION 1 x2 Running Board assembly - End caps (1 left & 1 right) - T-Nut Insert (x2) - S-style clips (x2) 2 x2 Motor Linkage Assembly (Rear) www.amp-research.com 3 x2 Idler Linkage Assembly (Front) 3/15 IM76140 rev 01.14.22 AMP RESEARCH POWERSTEPTM FORD RANGER / BRONCO 4 Wire Harness 5 Controller STA 6 ODB II Plug 7 x2 Motor 8 x2 Motor Cover 9 x4 LED Lamp 10 x8 Socket Cap Screw www.amp-research.com 11 x2 Posi-LockTM(Grey) 12 x2 Posi-TapTM (Red/Black) 4/15 13 x 8 Hex Flange Bolt IM76140 rev 01.14.22 AMP RESEARCH POWERSTEPTM FORD RANGER / BRONCO 14 x6 Cinch Fastener 15 x20 Cable Tie 7" 16 x2 Cable Tie 11" 17 x5 Grommet 18 x4 M8 Head Hex Bolt 19 x8 Butt Connector www.amp-research.com 5/15 IM76140 rev 01.14.22 AMP RESEARCH POWERSTEPTM FORD RANGER / BRONCO Locate Front Idler linkage location. If plastic plugs are present remove plastic plugs to expose threads. Pre thread supplied M10 flange bolt and hook linkage (3) over bolt as shown. Once linkage is in position thread in rear linkage mounting bolt (13). Snug up bolts but do not torque. 1 2 Locate Rear Drive linkage location. If plastic plugs are present remove plastic plugs to expose threads. Pre thread supplied M10 flange bolt (3) and hook linkage over bolt as shown. Once linkage (2) is in position thread in rear linkage mounting bolt. Snug up bolts but do not torque. 3 www.amp-research.com 6/15 IM76140 rev 01.14.22 AMP RESEARCH POWERSTEPTM FORD RANGER / BRONCO Install Running Board (1) to linkages. Ranger: Measure approx. 4.5" from back of linkage to tip of board. Bronco: Measure approx. 9.5" from back of linkage to tip of board. In order to prevent binding follow the steps below. Note: Hand cycle Boards between each step. 1. Tighten socket cap screws (10) with 3/16" Allen wrench. Torque to 10ft-lbs. 2. Rear Linkage: Tighten and torque Linkage upper mount bolt closest to pinch weld Torque to 30ft-lbs. 3. Front Linkage: Tighten and torque Linkage upper mount bolt closest to pinch weld. Torque to 30ft-lbs 4. Rear Linkage: Tighten and torque Linkage upper mount bolt closest to floor of cab. Torque to 30ft-lbs. 5. Front Linkage: Tighten and torque Linkage upper mount bolt closest to frame of truck. Torque to 30ft-lbs. 6. Hand cycle boards to ensure no bind is present. 1 2 1 3 4 5 6 7 8 1 1 2 3 4 5 6 7 8 9 10 11 4 Ford Ranger Install motor onto linkages using supplied Hex head bolts (18). Torque to 36in-lbs. (See page 2 for motor install) Ford Bronco Remove Fuse from powerstep wire harness. Remove fuse. 5 www.amp-research.com 6 7/15 IM76140 rev 01.14.22 AMP RESEARCH POWERSTEPTM FORD RANGER / BRONCO IMPORTANT NOTE! Ford Ranger follow steps 7 through 13. Ford Bronco skip to step 14. Ford Ranger ONLY: Mount controller using supplied zip ties to harness in front of battery as shown. Connect positive leads from harness. Red to positive battery terminal and black to negative battery terminal. 7 Route the two wire harness legs down over to each wheel well. Long leg will run across to passenger side, short leg will run down to driver side. Ensure loom is free from steering and exhaust components. 8 www.amp-research.com 8/15 IM76140 rev 01.14.22 AMP RESEARCH POWERSTEPTM FORD RANGER Ford Ranger ONLY: Remove floor mat and sill plate cover to expose floor below. 9 Locate hole forward of rubber plug. Approx location is in footwell area of cab. Use a 9/32" drill bit and drill thru floor. While drilling lift carpet to ensure drill bit does not damage carpet inside cab. Insert provided grommet (17) and run trigger wires thru hole. Route wires towards kick panel area. 10 www.amp-research.com 9/15 IM76140 rev 01.14.22 AMP RESEARCH POWERSTEPTM FORD RANGER / BRONCO Ford Ranger ONLY: Bronco proceed to step 12 Locate OBD port and remove bolt and nut holding it in place with 8mm socket to gain better access to back side of plug. 11 Locate the following wires and connect with supplied Posi-TapTM to the following wire colors listed below. Factory Can Wire Grey with Orange Stripe Purple with Orange Stripe OBD Module wire Color White Wire Blue Wire 12 Use supplied Posi-LockTM connectors to attach the 2 purple wires of the obd harness to the main harness. Attach matching colors on the harness to the wires on the module. Lastly reinstall Factory OBD port removed in step 10. Plug in module to OBD port on the vehicle. Reinstall sill plate removed from step 8. 13 www.amp-research.com 10/15 IM76140 rev 01.14.22 AMP RESEARCH POWERSTEPTM FORD RANGER / BRONCO IMPORTANT NOTE! Ford Bronco continue here, step 14. Ford Ranger skip to step 18 on page 13. Ford Bronco ONLY: Mount controller using supplied zip ties to harness in front of battery as shown. Connect positive leads from harness. Red to positive battery terminal and black to negative battery terminal. 14 Route the two wire harness legs down over to each wheel well. Long leg will run across to passenger side, short leg will run down to driver side. Ensure loom is free from steering and exhaust components. 15 www.amp-research.com 11/15 IM76140 rev 01.14.22 AMP RESEARCH POWERSTEPTM FORD RANGER / BRONCO Ford Bronco ONLY: Peel back small conduit with 2 purple wires inside to approx. 8" from junction. Trim excess conduit and tape end. This will allow wires to be exposed beyond the grommet when inserting into the cab of the vehicle. Excess wire will need to be trimmed for this application after being inserted into the vehicle. Locate oval grommet on driver side of firewall and push out. Poke small hole in grommet and thread trigger wires into cab of vehicle. 16 Locate the following wires and connect with supplied Posi-TapTM to the following wire colors listed below. Factory Can Wire Grey with Orange Stripe 17 Purple with Orange Stripe www.amp-research.com OBD Module wire Color White Wire Blue Wire 12/15 IM76140 rev 01.14.22 AMP RESEARCH POWERSTEPTM FORD RANGER / BRONCO Ford Ranger and Bronco proceed here: Wire OBD II connector with Posi-Splice. OBD II Connector located below steering column. OBD II install: Use Supplied Posi-LockTM 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 below for a brief description. Powerstep Control Module Vehicle Port To Powerstep Motors To Vehicle Power (12V) Powerstep Connection Module Direct to Port Option To Vehicle Power (12V) To Powerstep Motors 18 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) 13/15 IM76140 rev 01.14.22 AMP RESEARCH POWERSTEPTM FORD RANGER / BRONCO For 4 Door Bronco and Ranger. On each side of the vehicle measure from the front edge of door line on the pinch weld to the specified lengths below. Measure at 16" for the front LED Light and 58" for the rear LED Light. NOTE: For 2 Door Bronco, measure at 16" for front LED Light and 38" for the rear LED Light. 19 1262"" 6548-3"/4" - Drill a 9/32" hole through the pinch weld at marked locations. Deburr all holes. After drilling apply paint to holes to prevent rusting. - Insert grommet into drilled holes. Insert lamp wires through the grommets. (Silicon lube will help wires slip through grommets). - Affix lamp to rocker panel surface. Make sure lamp is affixed to a flat, clean surface. 9 17 9 17 20 Using supplied butt connectors, connect the lamp wires. Red to Red, Black to Black. Once Crimped use heat gun to shrink tube. Close and wrap with conduit and electrical tape. Secure all loose wires with cable ties, with lamp wires pulled upward to avoid any wire snagging. 1923 21 www.amp-research.com 14/15 IM76140 rev 01.14.22 AMP RESEARCH POWERSTEPTM FORD RANGER / BRONCO Insert plug from wire harness (4) onto motor (7). Slide rubber grommet on wire harness into slot of motor cover (8). Insert motor cover onto motor. Use electrical tape to cover any exposed wire from the motor. Insert plastic push pin rivets (14) in mounting holes of motor cover (8). Use pliers to ease installation. NOTE: On 2 Door Bronco, tie up exra wires using supplied zip ties (15) to avoid wire snagging. 7 8 8 14 4 22 Reinstall Fuse. Check that all doors activate the Power Step and the LED Lights work when doors open and close. Reinstall any remaining trim panels. Reinstall fuse 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. 23 www.amp-research.com 12 15/15 IM76140 rev 01.14.22 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.