OPERATION – MAINTENANCE & PARTS MANUAL INDEX

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END DUMPOPERATION – MAINTENANCE & PARTS MANUALINDEXPAGE #i.ii.iii.iv.CONSUMER INFORMATIONGENERAL OPERATION INSTRUCTIONSDUMPING OPERATION INSTRUCTIONSBLANKSECTION ONE1-11-21-3LUBRICATION CHART AND INSTRUCTIONSSCHEDULED MAINTENANCE RECOMMENDATIONSSCHEDULED MAINTENANCE RECORDSSECTION TWOELECTRICAL SYSTEM2-12-22-32-42-5LIGHT HOUSING DRAWING AND PARTS LISTWIRING SCHEMATIC WITH ISO PLUGWIRING SCHEMATIC FOR A FOUR-WAY VALVEWIRING SCHEMATIC AND PARTS LISTBLANKSECTION THREEGATE SYSTEM3-13-23-33-43-5GATE CONVERSION INFORMATIONCONVERTING FROM HIGH LIFT TO SIDE HINGECONVERTING FROM SIDE HINGE TO HIGH LIFTCOMBINATION GATE ASSEMBLYUPPER HINGE ASSEMBLY FOR COMBINATION AND GRAVITYGATES

3-63-73-83-93-103-113-123-133-143-153-16SELF ALIGNING SIDE HINGE GATE ASSEMBLY FOR COMBINATIONGATEGATE CLAMP ASSEMBLY FOR COMBINATION GATEHIGH LIFT GATE ASSEMBLYHIGH LIFT VALVE ASSEMBLYGATE AIR LOCK ASSEMBLYLOWER LATCH ASSEMBLIES4 INCH AIR CYLINDER4 INCH SINGLE ACTION PISTON SEAL KIT4 INCH ROD SEAL KIT4 INCH DOUBLE ACTION PISTON SEAL KITBLANKSECTION FOURAIR BRAKE SYSTEM4-14-24-34-44-54-6 – 4-43ABS INFORMATION PAGEFRAMELESS AIR BRAKE SYSTEMSINGLE POINT FRAMELESS AIR BRAKE SYSTEM WITH 3RD AXLEAIR RIDEQUARTER FRAME AIR BRAKE SYSTEMBLANKMERITOR WABCO ABS BRAKE MAINTENANCE MANUALSECTION FIVEAXLE SYSTEM5-15-25-35-4AXLE SYSTEM INFORMATION PAGETYPICAL AXLE DRAWINGTYPICAL AXLE PARTS IDENTIFICATIONBLANKSECTION SIXSUSPENSION SYSTEM6-16-26-36-4SUSPENSION INFORMATION PAGESINGLE POINT H900 SUSPENSION DRAWINGSINGLE POINT H900 SUSPENSION PARTS LISTINGBLANK

SECTION SEVENDRAFT ARM HINGE POINTS7-17-27-35TH PLATE TO DRAFT ARM CONNECTIONDRAFT ARM TO CENTER BOLSTER PLATEDRAFT ARM TO LEVELING ARM CONNECTIONSECTION EIGHTMISCELLANEOUS PARTS8-18-28-38-48-58-68-7SINGLE ACTING TELESCOPIC CYLINDER OPERATIONASPHALT APRON DRAWING AND PARTS IDENTIFICATIONFRONT FENDER ASSEMBLY DRAWING AND PARTS LISTREAR FENDER ASSEMBLY DRAWING AND PARTS LISTMUD FLAP BRACKET ASSEMBLYHIGH LIFT MUD FLAP BRACKET ASSEMBLYBLANKSECTION NINESPECIAL OPTIONSIF YOUR TRAILER HAS ANY OF THE FOLLOWING SPECIAL OPTIONS THEDRAWINGS AND PARTS LIST FOR THOSE ITEMS CAN BE FOUND IN THIS SECTION:TARP9-19-29-39-4CRAMARO TARPAULIN PAGE 1CRAMARO TARPAULIN PAGE 2CRAMARO TARPAULIN PAGE 3CRAMARO TARPAULIN PAGE 4

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CONSUMER INFORMATIONREPORTING SAFETY DEFECTSIF YOU BELIEVE THAT YOUR VEHICLE HAS A DEFECT, WHICH COULD CAUSE A CRASH OR COULDCAUSE INJURY OR DEATH, YOU SHOULD IMMEDIATELY INFORM THE NATIONAL HIGHWAY TRAFFICSAFETY ADMINISTRATION (NHTSA) IN ADDITION TO NOTIFYING RANCO TRAILERS.IF NHTSA RECEIVES SUFFICIENT SIMILAR COMPLAINTS, IT MAY OPEN AN INVESTIGATION AND IF ITFINDS THAT A SAFETY DEFECT EXISTS IN A GROUP OF VEHICLES, IT MAY ORDER A RECALL ANDREMEDY CAMPAIGN. HOWEVER, NHTSA CANNOT BECOME INVOLVED IN INDIVIDUAL PROBLEMSBETWEEN YOU, YOUR DEALER OR RANCO TRAILERS.TO CONTACT NHTSA, YOU MAY EITHER CALL THE AUTO SAFETY HOT LINE TOLL FREE AT 1-800-4249393 (OR 366-0123 IN WASHINGTON DC AREA) OR WRITE TO NHTSA, U.S. DEPARTMENT OFTRANSPORTATION, WASHINGTON, D.C. 20590. YOU CAN ALSO OBTAIN OTHER INFORMATION ABOUTMOTOR VEHICLE SAFETY FROM THE HOT LINE.GENERAL INFORMATIONMAINTENANCE SHOULD BE PERFORMED BY A RANCO DEALER OR OTHER QUALIFIED SERVICEFACILITY THAT REGULARLY PROVIDE SUCH SERVICE. ALTERATIONS TO A RANCO TRAILER SHOULDNOT BE MADE WITHOUT FIRST CONSULTING RANCO.ALTERATIONS COULD AFFECT THE STRUCTURAL INTEGRITY OF THE TRAILER AND VOID THEWARRANTY. WELDING OR OTHER ALTERATIONS SHOULD NEVER BE MADE TO ANY AIR RESERVOIR,WHEEL, RIM, AIR CHAMBER OR SPRING.THE GROSS AXLE WEIGHT RATING (GAWR) THAT IS STAMPED ON THE CERTIFICATE PLATE IS THESTRUCTURAL CAPACITY OF THE LOWEST RATED COMPONENT OF THE SUSPENSION, SPRINGS, HUBS,DRUMS, WHEELS, RIMS, BEARINGS, AXLES OR TIRES.IF COMPONENTS ARE SUBSTITUTED THAT AFFECT GAWR AND ARE OF LESS CAPACITY THAN THOSEORIGINALLY INSTALLED, THE GAWR ON THE CERTIFICATE PLATE MUST BE LOWERED TO THECORRESPONDING LOWER CAPACITY BY ADDING AN “ALTERED VEHICLE” LABEL. IF COMPONENTSARE SUBSTITUTED THAT ARE OF EQUAL OR GREATER CAPACITY THAT THOSE ORIGINALLYINSTALLED, THEN THE GAWR LABEL NEED NOT BE CHANGED.PROTECTIVE FILMS SUCH AS PAINTS AND OTHER COATINGS, ARE NECESSARY TO PREVENTCORROSION AND TO PROTECT THE METAL SURFACES. TRAILERS THAT OPERATE IN ENVIRONMENTSTHAT ARE CONDUCTIVE TO SEVERE CORROSIONS MAY REQUIRE MORE OR DIFFERENT PROTECTIVECOATING THAT THOSE USUALLY APPLIED AS STANDARD. CHECK WITH YOUR RANCO DEALER ORTHE FACTORY FOR RECOMMENDATIONS ON COATINGS FOR CORROSIVE MATERIALS.THERE ARE “WARNING” AND “CAUTION” DECALS PROMINENTLY DISPLAYED ON ALL RANCOTRAILERS. THESE SHOULD BE FOLLOWED TO THE LETTER BY ALL PERSONNEL OPERATING ORWORKING ON THE VEHICLE.i.

OPERATION INSTRUCTIONS1.2.ii.OPERATOR PRE-START CHECKSA. BEFORE BACKING UNDER THE TRAILER, BE SURE THAT THE TRUCK 5TH WHEEL IS PROPERLYGREASED AND THAT THE 5TH WHEEL HEIGHT IS COMPATIBLE WITH THE 5TH WHEEL PINHEIGHTB. CHECK SPRING BRAKES TO INSURE THAT THEY ARE PROPERLY SET SO THAT THE TRAILERWILL NOT SLIDE BACK WHEN THE TRACTOR IS BACKED UNDER THE 5TH WHEEL. THISTRAILER IS EQUIPPED WITH SPRING BRAKES THAT WILL LOCK THE BRAKES WHEN ALL AIRLINES ARE DISCONNECTED FROM THE TRACTOR AND WILL ONLY RELEASE AFTER THE AIRPRESSURE IN THE AIR TANKS EXCEEDS 50 POUNDS.STARTING PROCEDURE AND CONTROLSA. AFTER BACKING THE TRACTOR UNDER THE TRAILER AND INSURING THAT THE 5TH WHEEL ISLOCKED BY ATTEMPTING TO PULL AHEAD, THE AIR LINES AND ELECTRICAL CONNECTORSSHOULD BE CONNECTED PROPERLY, ENSURING THAT THE SERVICE AND EMERGENCY GLADHANDS ARE CONNECTED TO THE SERVICE AND EMERGENCY GLAD HANDS ON THE TRAILER.ALL GLAD HANDS SHOULD BE COLOR CODED, SERVICE (BLUE) AND EMERGENCY (RED).AFTER PROPER CONNECTION IS MADE, THE VALVE IN THE TRACTOR THAT ALLOWS AIR TOFLOW TO THE TRAILER SHOULD BE OPENED.B. WHILE AIR PRESSURE IS BEING BUILT IN THE TRAILER TANKS, THE OPERATOR SHOULDPERFORM THE FOLLOWING INSPECTIONS AND PROCEDURES TO INSURE THAT THE TRAILER ISIN OPERATIONAL CONDITION WHEN THE AIR PRESSURE IS BUILT UP SUFFICIENTLY TORELEASE THE BRAKES.1. RAISE THE PARKING LEGS OF THE TRAILER TO THE TRAVEL POSITION. THIS CAN BEMANUAL OR CRANK.2. CHECK THE TIRES FOR PROPER INFLATION AND TO INSURE THAT THERE ARE NO CUTS ORBRUISES THAT WILL LEAD TO TIRE FAILURE ON THE ROAD. WHILE CHECKING THE TIRES,THE OPERATOR SHOULD ALSO OBSERVE THE LEVEL OF OIL IN THE STEMCO OIL SEALS(REFER TO LUBRICATION SECTION).3. TURN ON TRACTOR LIGHTS AND CHECK ALL TRAILER LIGHTS FOR PROPER OPERATION.REPLACE LIGHTS OR BULBS IN ANY THAT IS NOT OPERATING PROPERLY.4. AT THIS TIME THE AIR PRESSURE SHOULD HAVE BUILT UP SUFFICIENTLY TO HAVERELEASED THE BRAKES ON THE TRAILER. CHECK TO SEE THAT ALL FOUR BRAKES HAVEIN FACT RELEASED. IF THEY HAVE NOT RELEASE, CHECK TO SEE WHY AIR IS NOTGETTING TO THEM.5. AFTER BRAKES HAVE RELEASED, CHECK FOR AIR LEAKS. LISTEN FOR ANY AIR LEAKS INTHE AIR OPERATING SYSTEM AS WELL AS IN THE AIR BRAKE SYSTEM. ANY LEAK SHOULDBE FIXED PRIOR TO ATTEMPTING TO OPERATE THE TRAILER.

END DUMP OPERATIONCAUTION! END DUMP OPERATION CAN BE DANGEROUS!OPERATOR SHOULD BE ALERT AT ALL TIMES WHEN RAISING TRAILER AND WARN PERSONSTO STAND CLEAR. YOU MUST NOT OPERATE THIS EQUIPMENT UNLESS YOU HAVE BEEN TRAINED INITS OPERATION. REMEMBER! AN UNTRAINED OR CARELESS OPERATOR SUBJECTS HIMSELF ANDOTHERS TO DEATH OR SERIOUS INJURY. OPERATOR SHOULD FOLLOW THE SAFETY PRECAUTIONS INTHIS MANUAL AND THE PRECAUTIONS SET FORTH BY YOUR COMPANY.BEFORE DUMPING, OPERATOR SHOULD CHECK DUMP SITE FOR A FIRM LEVEL SURFACE.CHECK FOR OVERHEAD POWER LINES OR OTHER STRUCTURES THAT COULD BE A DANGER.CYLINDERS CAN NOT WITHSTAND SIDE PRESSURE FROM A DUMP UNIT LEANING. MAKE SURETHE TRACTOR TRAILER UNIT IS LINED UP STRAIGHT WITH EACH OTHER (NOT JACK KNIFED) WHENDUMPING. AVOID DUMPING IN A HEAVY CROSS WIND, DUMP WITH UNIT FACING INTO THE WIND.DO NOT OVERLOAD DUMP UNIT. THE LOAD MUST BE EVENLY DISTRIBUTED DURINGLOADING AND UNLOADING.THE OPERATOR SHOULD REMAIN AT THE CONTROLS DURING THE ENTIRE DUMPINGOPERATION. IF THE UNIT STARTS TO LEAN TO ONE SIDE, THE OPERATOR SHOULD IMMEDIATELYLOWER THE BODY. IT IS IMPORTANT TO FEATHER THE CONTROL VALVE INTO THE HOLD POSITIONTO AVOID A PRESSURE SPIKE IN THE CYLINDER.DO NOT JERK OR SLINGSHOT DUMP UNIT IN AN ATTEMPT TO FREE A STICKING OR FROZENLOAD. PULLING FORWARD (OR BACKING UP) AND HITTING THE BRAKES OR LOWERING THE BODYPART WAY AND THEN QUICKLY ENGAGING THE VALVE IN THE ―HOLD‖ OR ―RAISE‖ POSITION WILLCAUSE A TREMENDOUS PRESSURE SPIKE. THIS PRESSURE SPIKE MAY BULGE OR SPLIT ONE OF THELARGER STAGES OF THE CYLINDER.WHEN LOWERING A LOAD THAT IS STICKING, THE DUMP UNIT MUST BE FEATHERED DOWNSLOWLY TO AVOID A HIGH PRESSURE BUILD UP IN THE CYLINDER. DO NOT OPERATE CYLINDER ATPRESSURES ABOVE 2,000 P.S.I.THE UNIT MUST BE LOWERED COMPLETELY BEFORE MOVING. DO NOT DRIVE WITH P.T.O. ORHYDRAULIC PUMP ENGAGED.HYDRAULIC HOSES SHOULD BE INSPECTED REGULARLY AND REPLACE IF WORN ORDAMAGED. HYDRAULIC OIL SHOULD BE CHANGED REGULARLY.A LIGHT FILM OF OIL ON EACH PLUNGER OR STAGE OF A TELESCOPIC CYLINDER INDICATEDGOOD CYLINDER OPERATION. AFTER MANY CYCLES OF THE CYLINDER, A SMALL ACCUMULATIONOF OIL MAY BE NOTICED ON THE PLUNGERS OR SLEEVES AT THE HEAD NUTS. THIS SHOULD NOT BEMISTAKEN FOR PACKING LEAKAGECYLINDER SHOULD BE FREE OF ENTRAPPED AIR. IT IS ADVISABLE TO BLEED AIR FROMCYLINDER WEEKLY FOR A SMOOTH OPERATION.IF OSCILLATING 5TH WHEEL IS USED IT MUST BE BLOCKED SO IT WILL NOT OSCILLATE.iii.

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ULEDMAINTENANCE

Page 1-1HYDRAULIC CYLINDER PIVOT PINGREASE TWO PLACES5TH PLATE- DRAFT ARM CONNECTIONGREASE TWO PLACESDRAFT ARM- BOLSTER CONNECTIONGREASE TWO PLACESHIGH LIFT GATE HINGEGREASE FOUR PLACES7.6.5.GATE LATCH HOOKGREASE TWO PLACESGATE LATCH CROSS SHAFTGREASE THREE PLACESAXLE BRAKE CAMGREASE FOUR PLACESEND DUMP LUBRICATION CHART4.3.2.1.

END DUMP TRAILERSCHEDULED MAINTENANCEThe following is a list of Scheduled Maintenance measures that if followed will help keep your RANCO TRAILER in good working order andwill result in a minimum of down time. These Scheduled Maintenance procedures are best performed at your DEALERS shop unless you havea qualified shop of your own capable of handling these procedures.AFTER 1st MONTH OF USETARP ADJUSTMENT - The cables and the tarp material tends to stretch once you start using the trailer. It is very important that the slack betaken out of the cables properly during this first check. -Refer to Tarp Adjustment Section on BACK of this page for adjustment recommendations.CHECK TORQUE ON ALL SUSPENSION FASTENERS - Once the trailer is placed in service; the fasteners stretch slightly andmay loose the torque values that were applied at the factory. It is important that these torque values be maintained in order for the suspension to operateproperly. The proper torque values for your suspension are listed in the Suspension Fasteners Section on BACK of this page and on a Decal attached tothe sub-frame of your trailer.CHECK TORQUE ON ALL WHEEL END FASTENERS - The wheel end fasteners stretch just like the suspension fasteners, andthe torque should be checked after the month of service. Refer to Wheel End Fasteners Section on BACK of this page for proper torque values fordifferent styles of wheels.GREASE GATE HINGES, AXLE CAM BUSHINGS & SLACK ADJUSTERS - Proper Lubrication is most important in theoperation of any type of dump trailer and a regular schedule should be set up and maintained. -Refer to Grease Section on BACK of this page, Page 1-4& 1-5 of this Manual & Yellow Decal on Trailer.CHECK FOR PROPER ADJUSTMENT AND OPERATION OF BRAKES - The air brake system is always set and checkedat the factory, but after being in use for a short period of time problems may show up, so brakes should be checked after 1 month and every 6 monthsafter that. - Refer to Air Brake Section on BACK of this page for the proper method of checking brake wear & settings.CHECK FOR PROPER OPERATION OF GATE SYSTEM - Refer to Operation of Gate System Section on BACK of this page.CHECK TIRES FOR PROPER INFLATION AND WEAR - Refer to Tire Section on BACK of this page for proper inflation andtread depth information.AFTER 6 MONTHS OF USE - REPEAT ALL CHECKS FROM 1st MONTHAT 1 YEAR OF SERVICE - REPEAT ALL CHECKS FROM 6 MONTHS OF SERVICEPage 1-2

Page 1-3TARP ADJUSTMENTSCHEDULED MAINTENANCE WORK SHEETRECOMMENDEDCHECKED BYDATECable TensionV-Belt or ChainTarp LengthBow AlignmentNot touching 18" ahead of rear pulleyFirm TensionStretched tightAll alignedCHECK TORQUE ON ALL SUSPENSION FASTENERS:H-900 SINGLE POINTRECOMMENDED TORQUESUSPENSION11/8" Trunion "U" Bolts880 ft. lbs.1" Trunion Hanger Bolts730 ft. lbs.3A" axle "U" Bolts300 ft. lbs.5/8" End Cap Bolts180 ft. lbs.H-970 (4 SPRING OR REYCO 886 SPRING SUSPENSION:300 ft lbs.155 ft lbs.50 ft. lbs.50 ft. lbs.CHECK TORQUE ON ALL WHEEL END FASTENERS:500 ft. lbs.500 ft. lbs.500 ft. lbs.7/8" Axle "U" Bolts5/8" Radius Rod Arm Clamp Bolts5/8" Spring Retainer Bolts1A" Radius Rod Arm BoltsInner Lug NutsOuter Lug NutsHub Piloted NutsGREASE GATE HINGES AXLE CAM BUSHINGS & SLACK ADJUSTERS:GREASEDDATEGREASEDGate BushingsCam Bushings & Slack AdjustersCHECK FOR PROPER ADJUSTMENT AND OPERATION OF BRAKES:Check Brake WearAmount of shoe remaining(New is 24/32-Min 8/32 requiredRECOMMENDEDCheck Push Rod AdjustmentCheck Brake DrumsCheck Brake OperationCheck ABS SystemNot more than 1-7/8" strokeNo cracks - excessive wearNo air leaks - All brakes operatingSee Book on SystemLFRF/32/32LRRRCHECKED BYDATE/32/32CHECK FOR PROPER OPERATION OF GATE SYSTEM:No leaks in hoses & fittingsNo hesitation or stickingCheck for air leaksCheck for smooth gateoperationCHECK ALL TIRES FOR PROPER INFLATION AND EVEN WEAR PATTERN:Check InflationCheck Tread DepthSee instructions on tire for proper inflation(Min. 4/32 /32DATE

SECTIONTWOELECTRICALSYSTEM

Page 2-12.1.ED4115 REAR LIGHT HOUSINGFRAMELESS (6‖ WIDE)ED4116 REAR LIGHT HOUSINGFRAMELESS (8 ½‖ WIDE)ED4045 CENTER LIGHT HOUSING FRAMELESSED4130 TANDEM QFED4117 TRI-AXLE QFLIGHT HOUSING

RED/BLACK STRIPE- BACK UP ALARMBLUE- GATE CONTROL VALVEORANGE- GATE CONTROL VALVE ON TWO VALVE SYSTEMWHITE- GROUNDBROWN- RIGHT TURNYELLOW- LEFT TURNRED- STOP LAMPSBLACK- CLEARANCE LAMPSWHITE/GREEN STRIPE- ABS LAMPEND DUMP PLUG SCHEMATICWITH ISO PLUGPage 2-2

Page 2-3TO GROUNDWIRING SCHEMATIC FOR FOUR WAY PLUGEND DUMP- SINGLE AND DOUBLE VALVETO BACK UP ALARMTO GATE LIFT AND GATE LOCK WHEN A SINGLE VALVEIS USED—TO LIFT GATE ONLY WHEN TWO VALVES AREUSEDTO GATE LOCK WHEN TO VALVES ARE USED

Page 2-41. 10205Y107002. 60215Y607003. 10205R107004. 40248R407005. 15009AMBER MARKER LAMPMARKER LAMP GROMMETAMBER MID TURN LAMPMID TURN GROMMETRED MARKER LAMPMARKER LAMP GROMMETSTOP, TURN & TAIL LAMPSTOP, TURN & TAIL LAMP GROMMETLICENSE LAMP ASSEMBLYWHITE- GROUNDBLACK- CLEARANCELAMPYELLOW- LEFT TURNGREEN- RIGHTBROWN- TAIL LAMPRED- STOP LAMPSBLUE- UNUSEDWIRING SCHEMATIC- END DUMP

Page 2-5THISPAGELEFTBLANKINTENTIONALLY

SECTIONTHREEGATESYSTEM

Page 3-1CONVERSION PROCEDURE FOR COMBINATION BARN/LIFT GATE!WARNING!THE GATE ASSEMBLY WEIGHS OVER 400 POUNDS SO SHOULD IT BECOME DISCONNECTEDFROM THE TRAILER AND FALL OFF IT COULD RESULT IN SERIOUS INJURY OR DEATH.TO INSURE SAFETY DURING THE CONVERSION, THE PROCEDURE INCLUDES TWO SEPARATEAND SIMULTANEOUS METHODS TO INSURE THAT THE GATE IS ALWAYS SECURED TO THE TRAILER,DO NOT DEVIATE FROM THE CONVERSION PROCEDURE OUTLINED BELOW.SINCE SEVERAL ¾‖ BOLTS ARE REQUIRED TO BE TORQUED TO 200 FT LBS, IT IS STRONGLYRECOMMENDED THAT A 1-1/8‖ HEAVY DUTY BOX WRENCH WITH A HANDLE LENGTH OF ABOUT 18‖OR A ¾‖ DRIVE RATCHET WRENCH WITH 1-1/8‖ HEX SOCKET BE USED FOR THE CONVERSIONPROCESS.GATES MUST BE FULLY CLOSED AND SECURED PRIOR TO BEGINNING THE CONVERSIONPROCEDURE. THIS REQUIRES THAT BOTH GATE LATCHES ARE LOCKED CLOSED OVER THE GATELOCK PINS AND THE FOUR SPOKE CLAMP IS IN POSITION ON THE FORKED GATE CLAMP PLATE ANDFULLY TIGHTENED SO THAT THE GATE IS CLAMPED AGAINST THE HALF ROUND BODY.FULLY CLOSING AND SECURING THE GATE SERVES TWO IMPORTANT FUNCTIONS:1. FULLY CLOSING THE GATE SHOULD ALIGN THE ALTERNATIVE HINGES CLOSE ENOUGHTHAT THE SELF ALIGNING PINS OR BUSHINGS CAN BE INSERTED FAR ENOUGH TO ENGAGETHE TAPERED SELF ALIGNING PROVISION AND ENGAGE ENOUGH THREADS ON THE ¾‖BOLT FASTENER TO SECURE THE GATE.2. SECURING THE GATE WITH THE AIR POWERED GATE LATCHES AND THE FOUR SPOKECLAMP PREVENTS THE GATE FROM COMING LOOSE FROM THE TRAILER REGARDLESS OFTHE CONDITION OF THE SELF ALIGNING PINS AND BUSHINGS.BOTH HINGE SYSTEMS ARE EITHER A TAPERED PIN OR A STRAIGHT BUSHING FITTING INTO ATAPERED COLLAR AS THE PRIMARY CONNECTING DEVICE.THESE TAPERED FASTENERS WILL PULL THE GATE INTO ALIGNMENT FROM A MISALIGNEDCONDITION OF UP TO 1/8‖ WHICH SHOULD NOT BE EXCEEDED UNDER NORMAL OPERATINGCONDITIONS OR MANY YEARS OF WEAR.THE TAPERED FASTENER SYSTEM IS ALSO DESIGNED SO THAT THE ALTERNATIVE TAPEREDFASTENER CAN BE ENGAGED AND TIGHTENED BEFORE THE ORIGINAL TAPERED FASTENER IS FULLYREMOVED.THIS INSURES THAT THE GATE IS ALWAYS SECURELY ATTACHED TO THE TRAILER DURINGTHE CONVERSION PROCESS.

CONVERTING FROM TOP HINGE LIFT GATE TO SIDE HINGE BARN DOOR 16.17.18.FULLY CLOSE THE GATE AGAINST THE HALF ROUND BODY.SWING THE FOUR SPOKE SIDE CLAMP OVER THE FORKED CLAMP PLATE ON THE GATEAND TIGHTEN THE CLAMP SECURELY.ACTIVATE AND CLOSE THE AIR POWERED GATE LATCHES OVER THE GATE LATCH PINS TOSECURE THE BOTTOM OF THE GATE TO THE TRAILERREMOVE THE TWO ¾‖ BOLTS AND THE TWO SELF ALIGNING TAPERED PINS FROM THEGATE ATTACHMENT PLATESREMOVE THE TWO ¾‖ BOLTS SECURING THE SIDE HINGE MOUNTING PLATES TO THE SIDEOF THE TRAILERROTATE THE SIDE HINGE MOUNTING PLATES 270 DEGREES FROM THE SIDE OF THETRAILER UNTIL THEY STOP AGAINST THE GATE MOUNTING PLATES.VISUALLY CHECK FOR ALIGNMENT WITHIN 1/8‖ BETWEEN THE HINGE GUIDE BUSHINGAND THE GATE RECEPTORCLEAN THE TAPERED PIN SURFACE AND IF NECESSARY THE GUIDE BUSHING ANDRECEPTOR.LUBRICATE THE TAPERED PIN AND ATTACHED THREADED FASTENER.INSTALL BOTH TAPERED PINS THROUGH THE GUIDE BUSHING AND INTO THE RECEPTORAND ENGAGE THE THREADED FASTENERS INTO THE RECEPTORBE SURE THAT THE TAPERED PIN FASTENER ENGAGES AT LEAST 4 THREADS (4 COMPLETE360 DEGREE ROTATIONS OF THE BOLT HEAD) BEFORE GETTING TIGHT. DO NOT FORCE IFSTRONG RESISTANCE IS FELT.IF STRONG RESISTANCE IS FELT OR IF THREADS CANNOT BE STARTED BECAUSEMISALIGNMENT IS GREATER THAN 1/8‖ THEN LOOSEN 4 SPOKE HAND WHEEL ONE TURNAND LOOSEN TOP HINGE BUSHING RETAINER BOLT 4 TURNS WHICH WILL ALLOW THEGATE TO BE PRIED TO WITHIN 1/8‖ ALIGNMENT.RETURN TO THE SELF ALIGNING TAPERED PINS AND FULLY TIGHTEN UNTIL THE PINFLANGE SEATS AGAINST THE GUIDE COLLAR.TORQUE THE SELF ALIGNING TAPERED PINS TO 200 FT LBS.INSTALL FOUR AUXILIARY ¾‖ CLAMP BOLTS THROUGH THE SIDE HINGE MOUNTINGPLATE INTO THE CAPTIVE NUTS IN THE GATE MOUNTING PLATE AND TORQUE TO 200 FTLBS.REMOVE THE TOP HINGE BUSHING COMPLETELY AND REINSTALL INTO THE FORWARDSTORAGE LOCATION IN THE BEARING PLATE AND TIGHTEN TO 100 FT LBS.TIGHTEN THE FOUR SPOKE CLAMP AGAINST THE FORKED GATE CLAMP PLATE.GATE IS NOW READY TO BE USED IN THE SIDE HINGE BARN DOOR CONFIGURATIONPage 3-2

Page 3-3CONVERTING FROM SIDE HINGE BARN DOOR TO TOP HINGE LIFT 16.17.18.19.20.21.22.FULLY CLOSE THE GATE AGAINST THE HALF ROUND BODY.SWING THE 4 SPOKE SIDE CLAMP OVER THE FORKED CLAMP PLATE ON THE GATE ANDTIGHTEN THE CLAMP SECURELY.ACTIVATE AND CLOSE THE AIR POWERED GATE LATCHES OVER THE GATE LATCH PINS TOSECURE THE BOTTOM OF THE GATE TO THE TRAILERREMOVE THE FOUR ¾‖ CLAMP BOLTS FROM THE HINGE TO GATE ATTACHMENT PLATES.REMOVE THE TOP HINGE BEARING BUSHING FROM THEIR STORAGE POSITION IN THEBEARING PLATE.CLEAN THE BUSHING SURFACE AND IF NECESSARY THE GATE BEARING AND TAPEREDCOLLAR AND BEARING PLATE INSIDE THE TAPERED COLLARCHECK THAT THE ALIGNMENT OF THE GATE BEARING AND TAPERED COLLAR AREWITHIN 1/8‖.LUBRICATE THE BEARING BUSHING AND ¾‖

3-6 self aligning side hinge gate assembly for combination gate 3-7 gate clamp assembly for combination gate 3-8 high lift gate assembly 3-9 high lift valve assembly 3-10 gate air lock assembly 3-11 lower latch assemblies 3-12 4 inch air cylinder 3-13 4 inch s

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