INSTALLATION INSTRUCTIONS SIDEWINDER BODY AND HOIST www.duraclass.com www.tbei.com www.tbeidumpbodyparts.com 1252726 1 20090828
IMPORTANT SAFETY NOTICE Proper installation, service, and repair are important to the safe reliable operation of DuraClass products. Installation and service procedures recommended by DuraClass are described in this service manual and are effective for performing installation and service operations. Some of these operations may require the use of tools or blocking devices specially design for the purpose. Special tools should be used when recommended. It is important to note that some warnings against the use of specific methods that can cause damage to the product or render it unsafe are stated in this manual. It is also important to understand these warnings are not exhaustive. DuraClass could not possibly know, evaluate, and advise the service trade of all conceivable ways in which service might be done or of the possible hazardous consequences of each way. Consequently, DuraClass has not undertaken any such broad evaluations. Accordingly, anyone who uses installation and service procedures or tools which are not recommended by DuraClass must first satisfy himself thoroughly that neither his safety nor the product safety will be jeopardized by the method he selects. DuraClass, as a manufacturer of the equipment that is covered by this manual, is providing a product to the user who has acknowledged to have superior knowledge of the conditions of the use to which the product will be put. DuraClass relies upon the user s superior knowledge in specifying any changes or modifications including, but not limited to, the inclusion or non-inclusion of options that are required by the user and the DuraClass product, and for the particular application of the user relative to the DuraClass product. The information and specifications included in this publication were in effect at the time of approval for printing. DuraClass reserves the right, however, to discontinue or change specifications or design at any time without notice and without incurring any obligation whatsoever. GENERAL INFORMATION The DuraClass Sidewinder is a multi-purpose body and hoist unit which can be used for conventional dump body applications as well as a material spreader. There are several options available to enhance the operation of the DuraClass Sidewinder, such as different cabshields, body screens, poly chute liner, spinner baffle kit, summer chute kit, and sliding doors for the tailgate. 1252726 2 20090828
BASIC DIMENSIONS The DuraClass Sidewinder is available in four standard lengths: 9, 10, 12, and 14. They are used on chassis from 84 to 96 C/A and 108 to 134 C/T respectively. Figure 1 and figure 2 show suggested dimensions for 10 and 14 bodies. Dimensions may vary as each installation can be different. The C/A or C/T can also be adjusted as necessary for extra cab clearance for an oil tank, wing plow cabinet, etc. Figure 1. Suggested dimensions for 10 body Figure 2. Suggested dimensions for 14 body 1252726 3 20090828
CYLINDER SUPPORT FRAME AND TIE DOWNS Place cylinder support frame back of cab as shown in Figure 3 so it fits squarely on the chassis and the cylinder will be oriented vertically when installed. It may be necessary to drill holes in base of support frame to clear rivet heads. Clamp support frame to chassis rail temporarily. Tack weld frame tie downs to support frame. Drill four 41/64 (16 mm) holes in chassis rail using holes in tie downs as a template. Bolt tie downs to chassis rail. Weld tie downs to support frame on three sides as shown. Note: DO NOT weld the support frame to the chassis rail. Remove clamps. Figure 3. Cylinder Support Frame Figure 4. Frame Tie Downs 1252726 4 20090828
BODY GUIDES Position body guides to clear body crossmembers. Drill four 41/64 holes in chassis rail, using holes in body guide as template. Bolt body guides in place. Figure 5. Body Guides REAR HINGE ASSEMBLY WELD NOTE ALL STRUCTURAL WELDING DONE IN THE INSTALLATION OF THE HOIST AND BODY SHOULD BE PERFORMED USING ONLY THE FOLLOWING RECOMMENDED WELD ELECTRODE AND WIRE. ELECTRODE E-7018 (THIS IS A LOW HYDROGEN ROD, AND MANUFACTURER S RECOMMENDATIONS MUST BE FOLLOWED.) WIRE E-70S-3 (WIRE MANUFACTURER S RECOMMENDATIONS MUST BE FOLLOWED.) Place the rear hinge on the truck frame. Make sure the rear hinge is correctly located and square with the truck frame and the telescopic cylinder mount. Cut the chassis as shown in Fig. 6. Center rear hinge and securely weld the rear hinge to the truck frame. If a pintle plate is not installed, box the end of the truck frame with ¼ thick plate (not supplied). 1252726 5 20090828
Figure 6. Rear Hinge Assembly 1252726 6 20090828
HYDRAULIC SCHEMATIC The DuraClass Sidewinder is designed to tie into a central hydraulic system. Hydraulic components supplied include hoses, fittings, and tubes for the side raise cylinders as well as the conveyor and spinner motors. Figure 7 shows a possible hydraulic schematic for the Sidewinder unit. Relief valve settings should be at 2500 PSI for the hoist, side raise cylinders, and rate control functions. A down side relief of 500 PSI is suggested for the side raise cylinders. Consult your central hydraulic system manufacturer for actual schematic and plumbing of remaining portions of the hydraulic system. Cab controls are not provided with the Sidewinder and will need to be sourced with the remaining hydraulic system components. Figure 7 Hydraulic Schematic 1252726 7 20090828
MOUNTING FRONT CHUTE AND SPINNER The spinner assembly and front chute are mounted on the left hand side of the chassis under the conveyor outlet on the body. Material from the body travels down the adjustable chute and onto the spinner assembly. The front chute is bolted to the chassis frame using four 1/2"-13NC x 2 grade five fasteners with lock nuts. Use the holes in chute mounting plate to drill holes. Locate and weld the front chute support to the chute mounting plate. It should be centered both vertically and horizontally. The chute can now slide on the support tube and be retailed with the hairpin cotter attached to the upper part of the chute (not shown in figure 8). Figure 8 Front Chute Support The spinner support is bolted to the chassis frame using four 1/2"-13NC x 2 grade five fasteners with lock nuts as shown in figure 9. Use the holes in spinner support mounting plate to drill holes. Figure 9 Spinner Support 1252726 8 20090828
The spinner assembly can then be attached to the spinner support using four 3/8-16NC x 1 grade five fasteners and lock nuts. Vertical adjustment is available with an extra set of holes in the spinner assembly and on the spinner support assembly. Two more of the 3/8-16NC x 1 grade five fasteners and lock nuts are used to attach the spinner guard to the spinner assembly. The spinner disc must have an upper hub assembly and lower plate attached with six 5/16-18NC grade five fasteners with luck nuts to allow mounting on the spinner assembly. Two 3/8-16NC x 2 grade five fasteners and lock nuts are used to attach the spinner disc assembly to the spinner assembly. Figure 10 Spinner Disc and Guard 1252726 9 20090828
BODY RAISED INDICATOR KIT OPTIONAL EQUIPMENT AS ORDERED Position body raised switch on the left side of the front of the hoist frame or the chassis frame. If attached to the hoist frame, the bracket may be welded or bolted in place. If mounted to the chassis frame, use the bracket as a template and drill two holes for 3/8 bolts. See Figures 11 and 12. Adjust the activating screw so that switch button is depressed about 3/16 and test for proper operation. Figure 11 Body Raised Indicator 1252726 10 20090828
Figure 12 Body Raised Switch 1252726 11 20090828
Mount back-up alarm as shown below in figure 13 using existing holes in bracket on rear hinge frame. Figure 13 Back-up Alarm 1252726 12 20090828
SPINNER BAFFLE KIT Locate spinner baffles around spinner guard making sure the baffle with the offset tab is located at the front. Bolt baffle brackets to baffles and weld brackets to spinner guard. Attach links to baffles and adjustment brackets. Weld adjustment brackets to spinner guard so baffles hang straight down when link is in its lowest position in the adjustment bracket. See figure 14. ITEM PART NO. DESCRIPTION QTY. 1 1551411 SPINNER BAFFLE 3 2 1532775 SPINNER BAFFLE - FRONT 1 HEX HEAD CAPSCREW 1/4-20NC X 3 1553050 3/4" 8 4 1514692 LOCK NUT 1/4-20NC 16 5 1535933 ADJUSTMENT BRACKET 4 6 1553490 BAFFLE BRACKET 8 7 1547945 LINK - BAFFLE 4 8 1583128 GUSSET 1 Figure 14 Spinner Baffle Kit 1252726 13 20090828
BODY SCREENS Install the ridge tube in the center of the body, level front to rear, with screen pin bearings toward driver s side. See figure 15. Figure 15 Ridge Tube Weld the provided angles on driver s side toprail to support fixed screen frames. Weld the screen hinge tubes on the passenger s side toprail spaced to match pin hinges on slide screen frames. See figure 16. Figure 16 Body Screens 1252726 14 20090828
Figure 17 Screen Part Numbers DuraClass, as a manufacturer of the equipment that is covered by this manual, is providing a product to the user who has acknowledged to have superior knowledge of the conditions of the use to which the product will be put. DuraClass relies upon the user s superior knowledge in specifying any changes or modifications including, but not limited to, the inclusion or non-inclusion of options that are required by the user and the DuraClass product, and for the particular application of the user relative to the DuraClass product. The information and specifications included in this publication were in effect at the time of approval for printing. DuraClass reserves the right, however, to discontinue or change specifications or design at any time without notice and without incurring any obligation whatsoever. 1252726 15 20090828