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Aluminum Headache Rack Instructions

Aluminum Headache Rack Instructions

11-1-14

 

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Aluminum Tank & Tank Accessories, Inc.

2702-B N. Nichols St., Fort Worth, TX 76106

800-773-3047   *   817-378-8455

www.attatank.com

 

Aluminum Headache Rack Installation Instructions.

 

SAFETY PRECATIONS:

 

*Read entire installation instructions prior to installation.

*Use proper eye and hand protection during any installation.

*Do not connect or disconnect any wires with ignition in the on position.

*Do not modify or substitute any component.

*Any questions regarding installation, please contact your dealer.

*Warranty will be voided if installation is not followed as per installation instructions.

 

REQUIRED TOOLS:

-3/4” Hole Saw and Drill

-3/4” Wrench

-3/8” Hex Bit

-Box Cutter

-Wire Strippers and Crimps

-1/2” Drill Bit

1.      Remove ¾” bolt and 3” washer from headache rack.

2.      Using a ¾” hole saw, drill a ¾” hole using attached diagram for your model truck for the wire harness. It may be necessary to file or remove any sharp burrs or edges from the hole.

 

Note: Some vehicle models have plugs and/or covers for the stake pockets. Carefully remove the plugs and covers from the top and side of the stake pockets.

3.      Carefully run the supplied wire harness through the drilled ¾” hole. Wire harness should follow through hole to underneath the truck body.

4.      Carefully place aluminum headache rack mounts to the inside of the trucks stake pockets. Note: The Aluminum Headache Rack is designed to fit snug.

5.      Using previous removed ¾” bolts and 3” washer, tighten bolts and washers to headache rack. NOTE: DO NOT CROSS THREAD OR OVER TIGHTEN BOLTS.

6.      Using supplied 3/8” Self-Tapping Screws, attach 3 per side. Do not over tighten.

7.      Route the wire harness containing (Green, White, Yellow, Brown, and Purple) to the rear of the truck. Ensure the wire harness is routed away from any moving parts or exhaust system. Use supplied wire ties, to secure harness.-Note, if aluminum headache rack has optional Duel LED Work Lights and/or 52” LED Light Bar, route supplied wire harness to the front of the truck.

 

Helpful reference guide to identify factory light wire color. NOTE: Not a complete list, please reference the owner’s manual for current wire colors.  

 

Wire Color by Vehicle Manufacturer (Reference Only)

Dual Purpose Bulb System

Wire Function

Wire Color

GMC

Ford

Chrysler

Jeep

Toyota

Honda

Mazda

Right Turn & Brake Lights

Green

Green

Orange w/ Blue Stripe

Brown

Brown

Green w/ Yellow Stripe

Green w/ Yellow Stripe

Green w/ Yellow Stripe

Left Turn & Brake Lights

Yellow

Yellow

Light Green Orange Stripe

Dark Green

Grey w/ Black Stripe

Green w/ Black Stripe

Green w/ Blue Stripe

Black Stripe

Tail Lights/

Running Lights

Brown

Brown

Brown

Black w/ Yellow Stripe or Black

Blue

Red w/ Green

Red w/ Black Stripe

Green or Black Stripe

Ground

White

Black

Black or Grey

Black

Black

Black or White

Black

Black

Single Purpose Bulb System

Brake Lights

Use Converter

Pink or Light Blue

Red w/ Green Stripe

White

Blue w/ Black Stripe

Green w/ Red or White Stripe

Green w/ White Stripe

Green or Green w/ Red Stripe

Backup Lights

Red

Lt Green

Black w/ Pink

Violet

Brown

-

-

-

Electric Trailer Brakes

Connect To Blue Wire From Brake Controller

 

 

 

(Trailer plugs for reference only)

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 8.      Using supplied Posi-Tap Tap Connectors, attach aluminum headache rack wires to corresponding factory haness colors.

 

GREEN to Right Turn/Brake

BROWN to Running

PURPLE to Reverse/Back-up

YELLOW to Left Turn/Brake

WHITE to Chassis Ground

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Optional Light Package Only:

For Use with Duel LED Works Lights and/or 52” LED Light Bar

9.      Inside Cab, Carefully drill a ½” hole for mounting of the rocker switch in desired location. (One rocker switch per light option) Ensure you are not drilling into a factory harness and no factory bracket will interfere with mounting of the rocker switch.

10.  Connect the Rocker Switch Green Wire to Chassis Ground. Connect Rocker Switch Orange Wire to 12 Volt Power Source. Note: Spare, Auxiliary, Upfitter, or SEO fuses are not used in any factory systems and should be used when adding any accessory part. Connect the remaining Rocker Switch wire harness(s) through the fire wall. Use a small grommet (not included) or factory rubber boot when routing wire through the fire wall to insure wires do not chaff or create a short. Insure the wires do not come in contact with any moving parts or exhaust componets. Connect the Rocker Switch Red wire to Headache Rack Red Wire.

 headache-rack-wire-diagram.jpg

 

IMPORANT NOTE:

The Aluminum Headache Rack is not designed for use as a safety device. Will not protect in the event of a roll over situation. The Aluminum Headache Rack is not designed to replace or substitute the factory lights. Please visit our website for the most current and up to date information, www.attatank.com.  

 

 

 

 

 

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Aluminum Tank and Tank Accessories

2702-B North Nichols
Ft.worth, TX 76106

Tollfree: (800) 773-3047

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