Thunder Power Tarp Kit Installation - Thunder 5000 Power Tarp … · 2016. 10. 19. · Using the...

011-52475 Rev L

Thunder Power Tarp Kit Installation

Dual Arm – Curb Side Stowing

Single Arm – Curb Side Stowing

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ARM INSTALLATION INSTRUCTIONS Note: This kit converts an existing manual crank system that has an existing locking extrusion on the roadside and tarp stops on the curbside into a one-touch system.

Preparation: 1. Roll the tarp to the covered position. 2. Remove the hand crank attachment from the back of the axle. 3. Remove the return mechanism(s) from the front and/or back of

the axle.

Note: Keep the handle attachment. If the motor is damaged, or the system cannot be powered, you can remove the motor, slide the attachment on to the adapter and pin it in place. This will allow you to use your hand crank as a backup. (The motor adapter will be installed in later steps.)

Install Tarp Axle Extension 1. Locate the 3’ (36in.) axle extension. The Axle Extension will be

swaged on one end. See figure 2.1.

2. If the current manual tarp system has a front bungee return, remove

the entire bungee cord, plastic guide, and 10' PVC tube from the front of your axle pipe and remove the eyebolt from the front of the Latch Plate.

3. Remove tarp clips along the length of the tarp axle tube and slide tarp axle tube forward 16”.

4. Insert the swaged end of the axle extension into the front of your tarp axle. If possible, weld axle extension to tarp axle and let cool fully before proceeding to next step. (If you cannot weld the extension into the roll tube, use the four ¼” x 1-¼” self-drilling Phillips head screws that are included in fastener bag to attach the extension). Attach the axle extension to the tarp axle in at least four places at 90 degrees from each other. See figure 3.1.

Swaged end

Fig. 2.1

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Questions? Contact Customer Service @ 402-435-4249

5. (Make sure Weld is cooled before sliding back into tarp!) Slide

axle back into tarp, and go to rear of trailer. Slide the tarp axle back until the end of the spline on the back of the axle is 19”-22” away from the end of the tarp. When the distance at the rear of the trailer is set, go to the front of the trailer and measure 15”-17” from the front of the tarp, and mark the axle. Cut the axle at mark and remove excess material. Remove the burrs from the end of the axle that was cut. (On a slanted rear system the rear distance is 33”-36” from the rear of the tarp and for a slanted front system the front dimension is 19 ½” from the front of the tarp to the extension end.)

Pivot Installation For single arm system only the front brackets and arms are installed.

1. On the front of the trailer measure from the bottom of the tarp cap,

for square nose trailers measure straight down approximately 23 ½” and put a mark on the front face of the trailer. This line should be as close to center as possible. Refer to the figure 3.2. For slant nose trailers measure approximately 25 ½” from the bottom of the tarp cap. Refer to the figure 5.4.

90 degrees from each other

Fig. 3.1

Fig. 3.2

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2. On the rear of the trailer measure from the bottom of the tarp cap, straight down 23 1/2” and put a mark on the rear face of the trailer as close to center as possible. Refer to figure 4.1. For slant nose trailers measure approximately 25 ½” from the bottom of the tarp cap. Refer to the figure 5.4.

3. Line up the top of the inner bracket with the top mark made in the

previous step. Remove existing rivets that will be behind bracket (6 fasteners total). Align the holes in bracket with holes on nose of trailer and bolt in place using four (3/8” button head bolts, 3/8” washers, and 3/8 nylock nuts) provided. The pivot point can be +2” to roadside -1” to curbside from the horizontal dimensions shown.

4. Remove four of the rivets from the rear wall of the trailer (leave middle rivets in place) bolt in place using four (3/8” bolts, plastic washers, washer, and nuts) provided. The pivot point can be +2” to roadside -1” to curbside from the horizontal dimensions shown.

5. If you have a square nose trailer bolt the outer brackets to the inner bracket using the four (1/2” hex head bolts, nylock nuts, washers) provided. It will appear as shown in the figure 4.2.

Inner Bracket

Outer Bracket

Fig. 4.1

Fig. 4.2

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6. If you have a slant nose trailer, bolt the outer brackets on using the

two lower rear-most bolts. Then rotate the brackets down until the top holes on the outer bracket line up with the forward-most holes on the inner bracket. It will appear as shown in figure 5.4.

Note: The angle of the bracket is opposite the ladder

side on both the nose and rear of the trailer.

Nose Rear

Fig. 5.1

Fig. 5.3 Fig. 5.2

Fig. 5.4 25 ½”

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7. Drill a 7/8” hole in the nose of trailer using hole in bracket as a guide. This will be used for wire to pass through.

8. On the front bracket insert ¼” groove grommet into hole on slanted leg of outer bracket. Put 3/8” groove grommet into the hole in nose/bracket. As shown in figure 6.1.

Adapter Assembly

1. Locate the adapter extrusion. Refer to figure 6.2.

2. Slide the long end of the adapter into the front of the existing tarp axle, if too long measure from the end of the axle extension to the adaptor extrusion stops. Remove excess extrusion from long end.

3. Slide the polymer bushing that is taped to the front arm onto the adapter extrusion as shown in figure 6.3. The bushing should slide on the end of the adapter that is closest to the stops that are welded on the adapter.

Front Arm Assembly

1. Locate front the knuckle arm assembly see figure 7.1 below. Bolt the motor to the arm assembly using the 6 provided 5/16” button head bolts and star washers.

Adaptor extrusion stop

Fig. 6.1

Fig. 6.2

Fig. 6.3

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2. Dab a small amount of DIELECTRIC GREASE on each of the motor

terminals. Attach the white striped wire to the + terminal of the motor and the black wire to the – terminal of the motor. Cover the terminals with the supplied boots.

3. With the arm hanging straight down, mount the pivot pin to the bracket through the 2 predrilled holes using the provided (1/2” button head bolts, washers and nylock nuts). Note the groove in the pin should point down. As shown in Figure 7.2.

4. At, the base of the arm near the bracket, install the spring pin into the

hole that is furthest to the left in the 3 hole pattern. When the arm is rotated up toward the axle, this will be the lowest hole. Lock into place with supplied cotter pin.

5. Rotate the pivot arm and motor up to the axle and slide axle adapter over the motor shaft. Make sure that the bushing is fully seated in the aluminum casting that is welded to the arm and pushed on the adapter all the way to the stops. The completed arm assembly will appear as shown in figure 7.3 when seen from the front of the trailer.

Rear Arm Installation

For single arm system only the front arms are installed.

1. Locate the Rear knuckle arm assembly. 2. With the arm hanging straight down, mount the pivot pin to the

bracket through the 2 predrilled holes using the provided (1/2” button head bolts, washers, and nylock nuts). Note the groove in the pin should point down.

Fig. 7.1

Fig. 7.2

Fig. 7.3

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3. Install the spring pin into the hole that is furthest to the left in the 3 hole pattern. When the arm is rotated up toward the axle, this will be the lowest hole. Lock in place with supplied cotter pin.

4. Install the rear arm bushing onto the back of the axle. The bushing may have to be tapped with a rubber mallet to get it passed the weld of the spline.

5. Rotate the pivot arm up to the axle and use the supplied U-bolt to secure the arm to the bushing. Make sure the lip of the bushing is seated firmly against the back plate of the arm.

Loading the Front and Rear Arms

1. Rotate the base arm up until the knuckle is folded far enough to

insert the short spring pin into the bottom hole. Insert the pin and secure with the supplied cotter pin as shown in figure 8.1. Front Arm Rear Arm

2. Rotate the lower arm back down and insert the long knuckle pin into the anti-rollover plates as shown in figure 8.3. Front Arm Rear Arm

Fig. 8.2

Fig. 8.3

8.1

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Arm Wiring 1. Run the wire that is pre run through the front arm through the two

holes in the front bracket Make sure the grommets are installed before running the wire to prevent the wire from being damaged by rubbing in the aluminum hole. Leave enough wire slack.

2. Using the rubber coated clips route the wire as shown in the pictures below.

Mount the Tarp Control Box

1. On the nose of the trailer, drill a 1 ¼” hole approximately 5” up from the top of the lower frame rail and 6” in from the edge of the round roadside corner post. (It is recommended that you drill the holes in this step from the inside out to avoid nicking a wire or air hose on the inside of the nose.)

2. Install grommet into hole to prevent wire damage. 3. Place the tarp control box up to the nose

of the trailer. 4. Locate the tarp control box approximately

6” – 8” above the 1 ¼” hole that was drilled in the nose of the trailer.

5. Drill three 17/64” holes in the nose of the

Insert 3/8” groove grommet

Insert 1/4” groove grommet

Fig. 9.1 Fig.9.2

Fig. 9.3

5”

6”

6” – 8”

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trailer using the tarp control box as a template. 6. Install 3 nylon spacers between tarp control box

and wall panel then fasten the tarp control box to the nose of the trailer using the three ¼”-20 x 1 ½” Phillips pan head screws, the ¼” lock washers, and ¼”-20 nuts.

7. Make sure that all fasteners are tightened. 8. Pull the four tarp control box wires through the

grommet hole into the trailer nose. Install the 2-Pole Receptacle

1. On the nose doubler plate (where the air & power are), mark a position that will allow the 2-pole receptacle to be installed. (It is recommended that you drill the holes in this step from the inside out to avoid nicking a wire or air hose on the inside of the nose.) Drill a 2 1/8” hole for the receptacle body to go through.

2. Slide the receptacle through the hole in the nose and mark where the holes for the screws will go. Drill a 9/32” hole for each of the screws. Insert the receptacle and attach using the ¼” x 1 ½” Phillips head screws, ¼” nuts, and ¼” lock washers.

Mount the Junction Box

1. Choose a location inside the nose of the trailer between two Z-posts close to the power receptacle so that all wires can reach the junction box.

2. Clean posts with a wire brush where plate will be installed.

3. Clamp the plate to the z-posts using vice grip pliers or clamp to hold in place.

4. Use four #10 x ¾” self-tapping screws to attach the mounting plate to the z-posts.

Wiring – Junction Box

1. Slide compression fittings onto all four motor wires.

2. Strip back 3/8”- ½” insulation on the red (M1) and black (M2) wires from the control box and the motor then install the 3/8” lug connectors using wire crimpers. Apply heat shrink to the connectors using a heat gun or torch.

Reference placement shown

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3. Pull the M1 & M2 wires from the tarp control box through the left side of the junction box and the wires coming from the motor into the right side of the junction box.

4. Slide the plastic nuts over the wires. 5. Secure all the motor wires to the

connector blocks in the junction box using 3/8”X16 nuts. Make sure to match black wire to black wire and red wire to striped wire.

6. Slide the compression fittings into the junction box and tighten the plastic nuts.

7. Install the junction box lid with the supplied screws. Wiring – 2 Pole Receptacle

1. Strip back 3/8” - ½” insulation on the BAT+ and BAT- wires coming from the tarp control box.

2. Place large rubber boot over the BAT wires and 8” 16GA ground wire.

3. Insert the BAT+ wire into the top terminal hole on the 2-pole receptacle and tighten the set screw securing the wire. (Use dielectric grease on the wire prior to inserting into the power receptacle)

4. Insert the BAT- wire along with the 16GA ground wire into the bottom terminal hole on the 2-pole receptacle and tighten the set screw securing both wires. (Use dielectric grease on the wires prior to inserting them into the power receptacle)

5. Slide the large rubber boot up to cover the back of the 2-pole receptacle.

6. Remove a ¼” nut and lock washer from one of the bolts holding the doubler plate to the z-post.

7. Apply dielectric grease around

the bolt and use the lock washer

and ¼” nut to attach the 8” 16GA

ground wire to the z-post.

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Place provided warning label in clear view above the tarp control box for safety.

Finalize Axle Assembly 1. Rotate the motor shaft into a position that the bolt can be inserted

through the axle adapter and motor shaft. Bolt the motor to the adapter using the 3/8” grade 8 bolts supplied with the motor. Tighten the bolt until it is very snug.

2. Run the motor in each direction for about 10 seconds to self-center the axle in the front and rear arms.

3. Once in place, use the ¼” x 1-1/4” supplied thread cutting fasteners (or Thunder specified stainless steel rivet) to attach the adapter to the existing axle. Use a minimum of six fasteners (3 and 3, 180 degrees apart as shown in figure 12.1.) to ensure a secure mount.

4. Slide the second locking collar behind the rear arm bushing. 5. Attach the locking collars on each side of the rear arm bushing

leaving approximately ½” to 1” gap between the clip and the front of the bushing and 2 ½” to 3” between the clip and the rear of the bushing to allow room for the arm to float slightly on the axle.

6. Replace all tarp clips using the supplied #10 x ¾” self-drilling screws. (NOTE: Make sure to screw tarp clips into the bottom of the tarp pipe

while tarp is fully extended.)

7A.

Fig. 11.1

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Crank Handle Retainer Installation

1. Assemble Crank Handle Retainer shown in Figure 13.1.

2. Attach to trailer using supplied 3/8” rib neck carriage bolts, washers,

and lock nuts as shown in figure 13.2. (If equipped with Hydraulic doors mount on curbside of trailer).

¼” x 1-1/4 Thread Cutting

2” Axle Extension Polymer Bushing

Adapter Extrusion

#10 x ¾” Self Drilling Screw

Tarp Strap

Tarp Clip

Fig. 12.1

Fig. 13.1

Fig. 12.2

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Placement of Corner Light Determine if you have the old style light shown in figure 13.3.

1. If you have the old style light, unfasten light from corner radius of

trailer. 2. Move light around the corner approximately 3”-4” or until the roll

tube extension clears the light See figure 14.1.

3. Refasten Light to corner radius of trailer.

Fig. 13.2

Fig. 13.3

Fig. 14.1

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Fasteners Included Qty. 1. Crank Handle Storage Kit

1.1. 3/8-16 rib shank carriage bolt 4 1.2. 3/8” lock washer 4 1.3. 3/8-16” nut 4 1.4. J-hook crank retainers 2

2. Aftermarket Electrical Kit 2.1. 2 pole receptacle 1 2.2. 2 pole boot 1 2.3. Control Box Assembly 1 2.4. ¼-20 x 1 ¼” stainless steel Phillips truss head 2 2.5. ¼-20 hex nut 2 2.6. ¼” split lock washer 2 2.7. Remote transmitter 1

3. Roll Tube Installation Kit 3.1. Screw #10 x ¾” Phillips head Self-drilling screw 15 3.2. ¼” x 1 ¼” SS Phillips pan head thread cutting 11 3.3. Locking Collar 2 3.4. Ø2” x 36” Extension tube 1

4. Front and Rear Bracket Installation Kit 4.1. Rubber covered clips 2 4.2. ¼-20 x 1 ¼” stainless steel Phillips truss head 2 4.3. ¼-20 hex nut 2 4.4. ¼” split lock washer 2 4.5. 3/8-16 x 1 3/4” button head bolt 8 4.6. 3/8” nylock nut 8 4.7. 3/8” flat washer 8 4.8. Nylon spacer 8 4.9. ½ x 1 ½” button head bolt 12 4.10. ½-13” nylock nut 12 4.11. ½” flat washer 20 4.12. Inner mounting bracket 2 4.13. Outer mounting bracket 2 4.14. Clevis Pin ½” x 2 ¾” 2 4.15. Clevis Pin ½” x 4 1/8” 4 4.16. Cotter Pin 6 4.17. Decal “Electric Tarp Operation Warning” 1 4.18. Decal “Manual Operation and Cautions” 1 4.19. Grommet 7/8” I.D. x 1 5/8” O.D. x 1/8” G.W. 1 4.20. Grommet 7/8” I.D. x 1 ¼” O.D. x ¼” G.W. 1 4.21. Grommet 7/8” I.D. x 1 1/8” O.D. x 13/32” G.W. 1

Tools Needed:

Standard Wrench Set Standard Deep-well Socket Set

Cordless Drill Hole saw set up to 2 ½”

Screwdriver Set Socket Extension

Wire Cutters Wire strippers/crimpers

Heat gun or torch

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Thunder Power Tarp Kit Installation - Thunder 5000 Power Tarp … · 2016. 10. 19. · Using the...

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