MANUAL OPEN RETROFIT INSTALLATION INSTRUCTIONS 40 /42 96 wide ag tub Timpte Hopper Trailers, Kit #100736 40 /42 96 wide split tub Timpte Hopper Trailers, Kit #100737 43 and longer 96 wide ag tub Timpte Hopper Trailers, Kit #100738 Thunderstone Manufacturing, LLC. 3400 West O Street Lincoln, NE 68528 402-435-4249 (Fax) 402-438-3918 www.thunderstonemfg.com THUNDERSTONE PART #100658 REVISION A January 21, 2014
TABLE OF CONTENTS REMOVE OUTER DOOR BEARINGS 3 HYDRAULICALLY OPEN DOORS ALL THE WAY..3 REMOVE THE DOOR 3 REMOVE DOOR PLATES 4 INSTALL NEW FASTENERS ON DOOR..4 ATTACH FORMED RACKS.5 REMOVE CYLINDER ROD MOUNTING BRACKET BEARINGS.5 CREATE HOLES TO ATTACH SHAFT ASSEMBLY BRACKET..6 ATTACH SHAFT ASSEMBLY.8 ATTACH CYLINDER RODS TO DOOR BRACKETS 9 TEST DOOR.10 Notes: The kit you purchased converts 2009 and newer Timpte trailers with EZ-Flow hydraulic doors to allow manualy cranking open the doors in case of system failure. Page 2 www.thunderstonemfg.com 402.435.4249
INSTALLATION INSTRUCTIONS 1. REMOVE OUTER DOOR BEARINGS. a. Remove the last two bearings (one on each side) toward the open end of the trap frame using 9/16 wrenches or a wrench and socket. This allows the door to be removed from the trap frame. 2. HYDRAULICALLY OPEN DOORS ALL THE WAY. a. The cylinder rods must be extended completely. 3. REMOVE THE DOOR. a. Turn the outer nut with a 15/16 wrench. It may be necessary to hold the inner nut or cylinder rod to keep the rod from turning. Do this to each cylinder rod. b. Pull the door completely out and place it upside down on the floor. 402.435.4249 www.thunderstonemfg.com Page 3
4. REMOVE DOOR PLATES. a. Using a die grinder with cutting wheel, cut a little more than halfway through the Huck collar. The cut should be as close to the bottom of the collar as possible for easy removal. b. Completely remove the cut fastener by striking it with a hammer. STEEL PLATES PLASTIC WEAR PADS UPSIDE DOWN DOOR WITH STEEL PLATES REMOVED 5. INSTALL NEW FASTENERS ON DOOR. a. While holding the door on its side, insert M6-1.0 x 35 flat head socket head cap screws through the existing holes. Install photos show 90 flush head Bobtail Huckbolts, BT90-R8-10GA (or regular 90 flush head Magnagrips, MGP90-R8-10G), which can be used in lieu of the cap screws, but appropriate Huck equipment is needed to engage the collars. b. To keep the fasteners from falling out hold a steel plate against the head of the fasteners and lay the plate on the floor (see top of next page). Page 4 www.thunderstonemfg.com 402.435.4249
STEEL PLATE 6. ATTACH FORMED RACKS. a. Replace the plastic wear pads over the new fasteners. There is no particular orientation of the pads. b. Place the formed racks on top of the plastic pads. The teeth of the racks are to the inside of the door, and the notched end of the racks are to the rear of the door, or the opposite end of the cylinder rod door brackets. c. Thread M6-1.0 nylon insert nuts onto the cap screws and tighten. Install photo shows Huck collars which are used instead of nuts when using Magnagrips. NOTCHED END ATTACH HUCK COLLARS (or nylon insert nuts) 7. REMOVE CYLINDER ROD MOUNTING BRACKET BEARINGS. a. Each trap frame has two hydraulic cylinders, and each cylinder is attached to the trap frame with two mounting brackets. There are roller bearings on the inside of the brackets, and their connecting bolts go through the cylinder rod mounting brackets. Some of these bearings will be removed, depending upon the type of trailer as follows and the diagram on top of the next page. On 36-42 ag tub trailers, remove the cylinder mounting bracket roller bearing closest to the open end of the trap frame, and also the one in front of it. On 36-42 split tub and 43 + ag tub trailers, remove both cylinder mounting bracket bearings. 402.435.4249 www.thunderstonemfg.com Page 5
CYLINDER ROD MOUNTING BRACKET REMOVE THESE ON 36-42 AG TUB TRAILERS REMOVE THESE ON 36-42 SPLIT TUB AND 43 + AG TUB TRAILERS 8. CREATE HOLES TO ATTACH SHAFT ASSEMBLY BRACKET. The shaft assembly bracket is mounted using one of the cylinder rod mounting bracket holes (rear for 36-42 split and 43 + ag tubs, front for 36-42 ag tubs), but the second hole cannot be used. Shown below is a shaft assembly the rearmost cylinder bracket mounting hole. Notice that another hole must be marked and drilled. Be sure to choose the hole for your trailer type. OPEN END OF TRAP FRAME FRONT-MOST CYLINDER MOUNTING BRACKET HOLE CANNOT BE USED REAR-MOST CYLINDER MOUNTING BRACKET HOLE USED Page 6 www.thunderstonemfg.com 402.435.4249
a. Measure and mark a hole 1/2 up from the bottom of the lower rail and 6-1/2 in front of the rearmost empty cylinder mounting bracket hole. Do this to both roadside and curbside trap frame rails. OPEN END OF TRAP FRAME 6-1/2 1/2 MARK HOLE REAR-MOST CYLINDER MOUNTING BRACKET BEARING HOLE b. Use a center punch to create a start for the drill at the mark, then drill through using a 25/64 bit. OPEN END OF TRAP FRAME CYLINDER BRACKET 25/64 BIT 402.435.4249 www.thunderstonemfg.com Page 7
9. ATTACH SHAFT ASSEMBLY a. The shaft assembly has a mounting bracket on each end. Before hanging the assembly on the trap frame, ensure that the shaft vertical bolts are all the way up the vertical adjustment slots as shown in the figure below. Tighten the nuts on the bolts. b. Hang the shaft assembly between the trap frame rails using the fasteners shown in the figure at the bottom. Do not tighten the fasteners yet. The view is from beneath on the road side of the trailer. SECURE THE BOLTS AT THE TOP OF THE ALIGNING SLOTS HYDRAULIC CYLINDER 3/8-16 LOCK NUT 3/8-16 LOCK NUT 10 mm WASHER NYLATRON ROLLER 10 mm WASHER 3/8-16x1-1/4 HX HD BOLT 10 mm WASHER 3/8-16x2 HX HD BOLT Page 8 www.thunderstonemfg.com 402.435.4249
b. Insert a door about halfway into the trap frame. As the door goes in the formed rack will engage the spur gears. c. Ensure that the teeth on each spur gear engage the same tooth location on the formed gear rack. In other words, if one gear tooth engages the third formed gear rack tooth from the end, the other gear must also engage the third formed gear rack tooth. Move the shaft assy. and door as needed to obtain correct alignment. d. When the teeth are aligned properly, tighten the fasteners that attach the shaft assembly bracket to the trap frame. Move the door back and forth to ensure the door moves smoothly. SPUR GEAR TEETH LINE UP IN SAME RACK TEETH 10. ATTACH CYLINDER RODS TO DOOR BRACKETS. a. Thread an adjusting nut onto the cylinder rods. Leave about four threads behind each nut. b. Extend the cylinder rods completely. This is done to ensure enough play at the ends of the rods. c. Guide the cylinder rods through the door brackets by pushing the door into the trap frame. It may be necessary to get one side in at a time. Push the door in far enough so that the bracket is against the nut. d. Thread and tighten a nut against the door bracket and push on a thread protector. ROD ADJUSTING NUT ROD ADJUSTING NUT THREAD PROTECTOR 11. TEST DOOR a. Open and close the door hydraulically to ensure smooth operation. If the door jumps or binds, the formed gear rack teeth may be misaligned with the shaft spur gears. Refer to step 9c to fix this. 402.435.4249 www.thunderstonemfg.com Page 9
PART NUMBER QTY DESCRIPTION 100736 1 EA KIT MANUAL OPENER EZ-FLOW HYD DOOR 40/42 AG TUB 96W 032-01297 1 EA BOLT 3/8-16 X 1 1/4 GRD 5 HXHD 032-01405 2 EA NUT 3/8-16 P-LOCK HXHD 032-03469 8 EA BOLT 1/2-13 X 1 1/2 GRD 8 FLANGE SERRATED 032-03472 8 EA NUT 1/2-13 FLANGED LOCKING 032-37870 3 EA WASHER.413 X.787 X.078 M10 METRIC SS 032-38239 1 EA BOLT 3/8-16 X 2 SS GRD 5 HXHD 032-44745 1 EA WASHER 1 OD.406 ID SS 032-56063 2 EA PIN GROOVE TYPE E 3/8X1-1/2 STL ZNCPL 034-47167 4 EA NYLATRON ROLLER 1.5 OD X 0.400 ID X 1/2 WIDTH NYLATRON GS 034-55916 4 EA CAP ROUND.625IDX.76ODX1 LONG VINY BLACK CAPLUG #VC-625-16 035-48979 4 EA BEARING-2 BOLT FLANGE - 1 ID 45 / BOX 035-55900 2 EA NUT HEX DRIVE 1.5X1.025X1.375L STL ZNC PLT YLW CHROMATE LG2138-01 050-55915 4 EA PLATE BEARING MTG EZ-FLOW EMER OPEN 051-56590 4 EA RACK FORMED 34 ¾ UNIVERSAL 100746 16 EA SCREW M6-1.0 X 35 FLAT HEAD SOCKET CAP A2 SS 100747 16 EA NUT M6-1.0 NYLON INSERT L/N ZINC 365-47138 2 EA SHAFT CROSS AY - AG 96W GEAR RACK AND ROLLER DOOR OVERALL LENGTH - 29 3/4 PART NUMBER QTY DESCRIPTION 100737 1 EA KIT MANUAL OPENER EZ-FLOW HYD DOOR 40/42 SPLIT TUB 96W 032-01297 1 EA BOLT 3/8-16 X 1 1/4 GRD 5 HXHD 032-01405 2 EA NUT 3/8-16 P-LOCK HXHD 032-03469 8 EA BOLT 1/2-13 X 1 1/2 GRD 8 FLANGE SERRATED 032-03472 8 EA NUT 1/2-13 FLANGED LOCKING 032-37870 3 EA WASHER.413 X.787 X.078 M10 METRIC SS 032-38239 1 EA BOLT 3/8-16 X 2 SS GRD 5 HXHD 032-44745 1 EA WASHER 1 OD.406 ID SS 032-56063 2 EA PIN GROOVE TYPE E 3/8X1-1/2 STL ZNCPL 034-47167 4 EA NYLATRON ROLLER 1.5 OD X 0.400 ID X 1/2 WIDTH NYLATRON GS 034-55916 4 EA CAP ROUND.625IDX.76ODX1 LONG VINY BLACK CAPLUG #VC-625-16 035-48979 4 EA BEARING-2 BOLT FLANGE - 1 ID 45 / BOX 035-55900 2 EA NUT HEX DRIVE 1.5X1.025X1.375L STL ZNC PLT YLW CHROMATE LG2138-01 050-55915 4 EA PLATE BEARING MTG EZ-FLOW EMER OPEN 051-55874 2 EA RACK FORMED 44 LEFT 051-55875 2 EA RACK FORMED 44 RIGHT 100746 24 EA SCREW M6-1.0 X 35 FLAT HEAD SOCKET CAP A2 SS 100747 24 EA NUT M6-1.0 NYLON INSERT L/N ZINC 365-47140 2 EA SHAFT CROSS AY - STD 96W GEAR RACK AND ROLLER DOOR (SHAFT ONLY) PART NUMBER QTY DESCRIPTION 100738 1 EA KIT MANUAL OPENER EZ-FLOW HYD DOOR 48/50 AG TUB 96W 032-01297 1 EA BOLT 3/8-16 X 1 1/4 GRD 5 HXHD 032-01405 2 EA NUT 3/8-16 P-LOCK HXHD 032-03469 8 EA BOLT 1/2-13 X 1 1/2 GRD 8 FLANGE SERRATED 032-03472 8 EA NUT 1/2-13 FLANGED LOCKING 032-37870 3 EA WASHER.413 X.787 X.078 M10 METRIC SS 032-38239 1 EA BOLT 3/8-16 X 2 SS GRD 5 HXHD 032-44745 1 EA WASHER 1 OD.406 ID SS 032-56063 2 EA PIN GROOVE TYPE E 3/8X1-1/2 STL ZNCPL 034-47167 4 EA NYLATRON ROLLER 1.5 OD X 0.400 ID X 1/2 WIDTH NYLATRON GS 034-55916 4 EA CAP ROUND.625IDX.76ODX1 LONG VINY BLACK CAPLUG #VC-625-16 035-48979 4 EA BEARING-2 BOLT FLANGE - 1 ID 45 / BOX 035-55900 2 EA NUT HEX DRIVE 1.5X1.025X1.375L STL ZNC PLT YLW CHROMATE LG2138-01 050-55915 4 EA PLATE BEARING MTG EZ-FLOW EMER OPEN 051-55874 2 EA RACK FORMED 44 LEFT 051-55875 2 EA RACK FORMED 44 RIGHT 100746 24 EA SCREW M6-1.0 X 35 FLAT HEAD SOCKET CAP A2 SS 100747 24 EA NUT M6-1.0 NYLON INSERT L/N ZINC 365-47138 2 EA SHAFT CROSS AY - AG 96W GEAR RACK AND ROLLER DOOR OVERALL LENGTH - 29 3/4 Page 10 www.thunderstonemfg.com 402.435.4249