Ramp-to-LL Install Instr (NEW) - Sturdy-Lite
Contents
1. Top of Socket Rod Figure 5 curb side Bridge Adapter with two shims installed and Socket Rod inserted through Top Pin Socket Ramp s end adapter hole and the Bottom Pin Socket in order 6 Locate four 4 Timber Tabs from your Conversion Kit and the two dunnage timbers required as per Step 2 of the Application Survey with the following length tolerance specs dependent on your Trailer width as follows 96 wide trailer length no greater than 91 1 2 no less than 89 1 2 102 wide trailer no greater than 97 1 2 no less than 95 1 2 Place the Timber Tabs spaced 19 apart onto the skyward face of the Ramp Leveler followed by the timbers placed between the Timber tabs in a side by side configuration as illustrated in Figure 6 10 4x4 dunnage timbers f Figure 6 Exploded amp Isolated View of Ramp Leveler with Timber Tabs and 4x6 Timber Verify that there is no protrusion of timber from either side Then using the tape measure measure the overall height of the Ramp Leveler with the timber s installed verifying that it is within 1 of the Total Drop Height TDH measurement from Step 2 of the previous Survey Section as this is required for use Under no circumstances whatsoever are you to use more than two 2 4x4 dunnage timbers side by side in the top channel of any Ramp Leveler as stacking timbers creates an inherently unstable structure If you cannot meet the above requirement and achie2. Figure 8 Illustrated view of 5 16 chain looped through slotted bar amp side rail pocket hooked at all ends amp slack minimized 16 Use the Load Binder s ratchet mechanism to make suspended chain segments on each side as taut as possible 17 Repeat Steps 10 through 16 for each Ramp Leveler placed along the lower deck after the foremost unit Note that you may deplete supplies from the chain amp Clevis hook sets in continuous fashion instead of opening a new packet for each Ramp Leveler all chains amp hooks are identical 18 Gathering all remaining chain amp hook set packets go to the curb side of the Trailer s lower deck and starting from the foremost unit perform the chain Clevis hook Load Binder assembly process as described in Steps 10 through 17 above 13 Usage and Maintenance Requirements Usage 1 You must obey the loading requirement directives listed on the Ramp Leveler s warning labels at all times Each Ramp Leveler was designed and manufactured using ASTM International and AWS written quality control specifications and procedures The satisfactory performance of each Ramp Leveler per the parameters specified on each unit s performance notification label as follows AS DESIGNED AND MANUFACTURED THESE RAMP LEVELERS BRIDGES ARE LOAD RATED FOR A UNIFORMLY DISTRIBUTED LOAD CAPACITY OF 20 000 LBS OVER AN 8 WIDE SPAN CONCENTRATED LOAD OF 9 500 LBS OVER VERTICAL POST 2 650 LBS ELSEWHERE UNIT MUST B
3. Sturdy Lite A Division of Roadmaster Enterprises LLC 1900 INDUSTRIAL BLVD BRISTOL TENNESSEE 37620 OFFICE 423 968 7021 FAX 423 968 3820 RAMP to RAMP LEVELER CONVERSION KIT FOR DROP DECK TRAILERS APPLICATION SURVEY INSTALLATION INSTRUCTIONS USAGE MANUAL Table of Contents Section starting page Important Safety Notices 2 Pre Install Application Survey 3 Installation Instructions 7 Usage and Maintenance Requirements 14 Uninstall amp Storage Procedures 15 gt Before using Sturdy Lite aluminum Loading Ramps as Ramp Levelers via Conversion Kit sold separately read this Manual in its entirety The end user You must ensure that all Sturdy Lite Ramp Levelers are installed used and stored per the procedures described within this Manual If you are unsure of how to follow any part of this Manual contact the distributor from whom you purchased your Ramps and or Conversion Kit with details on your trailer make model requested measurements etc so that they may properly advise as to selection and usage of the Conversion Kit specific to your Trailer The Federal Motor Carrier Safety Administration FMCSA specifies the minimum performance criteria for cargo securement devices and systems as managed by the U S Department of Transportation U S D O T in 393 102 of their Federal Regulations publication You are responsible for ensuring that cargo article weight limits and load shifting protection are with
4. adding onto the Effective Spacing distance 2 If the value of FSPD is greater than nine 9 inches you must install the foremost Ramp Leveler in the first pocket located forward of the Effective Spacing value as measured from the foremost Ramp Leveler and the drop deck wall in effect subtracting this distance from the Effective Spacing distance Each subsequent Ramp Leveler unit beyond this foremost unit will be simply spaced apart per the Effective Spacing value recorded in Step 8 b and installed in the pocket located within two inches of the ES distance for both sides of the trailer driver and curb side Mark the corresponding curb side pockets with rope string accordingly Note that while using the decision logic for accommodating the FSPD measurement above you must make sure that the spacing between 1 the drop deck wall amp the foremost Ramp Leveler on the lower deck and 2 each successive pairs of Ramp Levelers is as close in value of measured distance as possible for your Trailer Installation Instructions Supplies needed Qty 1 tape measure Qty 1 Torque wrench w torque measuring capability and socket for 5 8 dia bolt head used for securing bolts on trailer receiver NOTE Do not use an extension on the torque wrench as the actual torque applied to the bolt will not match the measured torque Qty 1 Open end or box end wrench used to temporarily restrain each nut as 5 8 bolt is secured Qty
5. calculator Qty 2 per Ramp Leveler unit 12 long lengths of rope or string for pocket place markers Obtain the value of the total weight of the cargo which you will be planning to haul using Ramp Levelers and record here as Total Cargo Weight TCW Ib You will refer to this TCW value in Step 6 From either side of the Trailer using the tape measure measure the height differential Drop Height between the upper and lower decks of your Trailer as shown in Figure 1 below Figure 1 Measuring the overall height differential DH between the upper and lower decks of your Trailer NOTE if you will have dunnage items on the upper deck for side un loading access the height of the dunnage should be added to the overall Drop Height DH measurement Record as Total Drop Height DH height of dunnage as placed on upper deck inches You must report this value to your sales representative when ordering a Conversion Kit Sturdy Lite Ramp to Ramp Leveler units are made to equal the Total Drop Height with or without dunnage on the Trailer s upper deck surface As such the Total Drop Height measurement must be within plus or minus one inch 1 of the overall height of each Ramp Leveler once appropriate timbers are installed in the Ramp Leveler s Timber Tabs For a 20 TDH you will need two 2 2x4 timbers ripped from a single 4x4 timber for each Ramp Leveler for a 24 TDH you will need two 2 4x4 timber
6. 1 per Ramp Leveler Ramp Leveler Conversion Kit sold separately Qty 1 per Ramp Leveler DOT approved 5 16 chain and Clevis hook sets four pairs per set Qty 2 per Ramp Leveler Load Binder 1 With the appropriate quantity of Ramp sections required for your Ramp Leveler hauling needs as determined from N per the previous Survey section placed onto your Trailer s lower deck take the Bridge Adapter that is solidly welded to a Stake Post and place the Post down into the foremost driver s side pocket marked with rope string With the ramp end miters sloping away from the drop i e the bottom face of the ramp facing toward the upper deck slide the ramp into the Bridge Adapter on the driver s side so that the 1 diameter holes are in line as seen in Figures and 2 Pin Socket holes aligned with socket hole of Ramp end piece adapter 8 Ramp Section Trailer Side Pocket Bridge Adapter Pin Socket Figure 1 Overhead View of Ramp End Adapter Aligned with Bridge Adapter Pin Socket BOTTOM FACE OF RAMP FACING TOWARDS THE UPPER DECK MITER SLOPE ORIENTATION RAMP LEVELER ASSEMBLY Figure 2 Perspective Overhead View of Drop Deck Trailer w Ramp Ramp Level 2 Take the 7 8 diameter Socket Rod and slide down into and through the Pin Socket holes until the head rests on the Pin Socket surface as illustrated in Fig 3 below 7 8 diameter Rod Handle Bridge Adapter Pin Socket iij i
7. E SECURED BY D O T 5 16 CHAIN IN CHAIN SLOTTED BRACKET PROVIDED The term uniformly distributed in the context of the above notification indicates that for the Ramp Leveler to perform a load supporting function at a capacity consistent with its spacing and configuration along with 1 other Ramp Levelers as prescribed in the Application Survey above 2 the Trailer s upper deck platform length availability 3 the total cargo length and weight 4 Regulations on the structural integrity and installation requirements of all securement items straps chains etc 2 The cargo must be configured in a manner such that the piece weight distribution of cargo is within a margin of 5 for each 12 inches 1 foot on either side of width span of a Ramp Leveler supporting cargo and all required units are spaced per the Survey above and installed per the Installation Procedure If you haul any cargo with a weight distribution across the width span of the Unit that is concentrated that is a cargo load with 15 or more of its weight being exerted within a width span of one foot 1 the primary load rating 20 000 Ibs total cannot be satisfied and liability of structural performance for such Ramp Leveler unit is disclaimed b Sturdy Lite 3 The Ramp Leveler must be secured and maintained per DOT 393 102 In short a system is only as strong as its weakest link You and your managing associates involved in the business of cargo
8. Ty Figure 3 Perspective Side View of Socket Rod Installed Through Pin Socket and Ramp Adapter 3 Take the Bridge Adapter with shims bolted between its channel and Stake Post and disassemble both of the bolt washer nut sets Then remove all shims and re assemble the bolt nut sets hand tightening is fine making sure that the carriage bolt is oriented such that its head is within the channel component this serves to temporarily re couple the Stake Post and Channel components With the ramp section aligned to the curb side side rail pocket marked with rope string hold this Bridge Adapter in a position such that the Post is inserted into the pocket and butted against the side rail channel amp braces set on the deck platform Using the tape measure approximately measure the distance between the center of the Ramp Leveler s end adapter hole and the pin socket hole within the channel as shown in Figure 4 DECK PLATFORM BRIDGE ADAPTER CHANNEL STAKE POST top l TAPE MEASURE PIN SOCKET Figure 4 Measuring the distance between a Ramp Leveler s curb side end adapter hole center and the center of the pin socket hole within the curb side Bridge Adapter s channel Record this measurement here as Socket Hole Offset SHO inches A one time adjustment will be required for configuring the curb side bridge adapter with shim plates such that the pin socket holes will align with the Ramp s end adapter hole and the interior face o
9. cross the width of the trailer Take each additional Ramp unit one at a time and place as close as possible to the unit just placed near the lower deck front again setting the unit on its bottom side As in step 1 take a ratchet strap with one end hooked or spooled to an anchor point on one side of the Trailer and run one end over the top of the ramp across the width of the trailer Once all Ramps have been placed together toward the drop deck wall and Ratchet Straps set in place per Step 1 you may return to ground level and starting from the driver s side of the Trailer using the ratcheting mechanism and the Trailer OEM s specified anchor points for strapping hooks secure each Ramp such that it cannot be moved laterally across the Trailer deck s width transversely forward backward along the Trailer s length or vertically up Verify from both the driver s side and the curb side of the Trailer for each unit that a the strapping unit is taut b the ratchet mechanism s lock device is engaged and c all anchor points for the strapping amp mechanisms are secure You should perform periodic checks of each Strap and Ratchet mechanism per 3 a c above verifying tautness of all straps and that all locks are engaged before and after traveling with the units stored in the manner specified above 2 method See Ramp Storage Rack User s Manual for installation instructions 15
10. d by TCW and CL UDL values Number of Ramp If CL UDL is Less than 13 Between 13 and 25 Between 25 and 37 Between 37 and 49 Levelers required N If TCW is Less than 30 000 lbs 1 2 2 Between 30 000 Ib and 1 40 000 Ib Between 40 000 Ib and 2 3 3 4 55 000 lb Between 58 000 lb and 3 4 4 5 75 000 lb Record as Number of Ramp Levelers N 8 a Take the value of CL UDL recorded in Step 6 and using the calculator divide this number by the value of N recorded in Step 7 Record here as Spacing Estimate SE ft b Now if the value computed for SE is not a whole number e g 12 333 and or is odd e g 13 it must be rounded down to the nearest even number consistent with your Trailer s lower deck side rail pocket spacing since many Trailer models have lower deck side rail pockets spaced apart at 2 feet 1 8 on center along the intermediate span of the lower deck the rounded down value would often result in a value such as 10 or 12 feet 9 Record this rounded down value here as Effective Spacing ES ft c Note that this rounding process will result in the rear most segment of the cargo being hauled to extend beyond the rear most Ramp Leveler this is acceptable for configuration while in use for hauling as long as the length of such segment is less than two feet If such length is greater than two feet you must examine the possibility of reposit
11. d of this chain 14 While holding the Load Binder up with one hand take the first two feet of the 48 chain from the Load Binder in your other hand and holding this segment taut place the link nearest the Ramp Leveler Bridge Adapter s slotted bar into the slot Then take the remaining loose segment and run it down into the side rail stake pocket aft of the Leveler Once you have taken the hook amp chain through the bottom opening of the pocket as far as the chain s length allows take the hook in hand and bring it up along the outside area near this pocket and secure the Clevis hook into the chain link which minimizes slack in the aft segment of chain 15 Similar to Step 11 wrap the remaining segment of the hooked end chain around the segment hooked to the Load Binder circling several times and inserting the Clevis hook s end into the nearest chain link available on the Binder hooked segment The results of Steps 10 through 15 here should look similar to that illustrated in Figure 8 oop chain through Stake Post s slotted bar g soe a he a loop chain through pocket amp inse levis hook through nearest chain ink so that loop has minimal slack loop chain through pocket amp insert Clevis hook through nearest chain link so that loop has minimal slack Using Load Binder ratchet the two chain sections toward the other so that both are taut 12 Figure 7 Example view of 5 16 chain looped th
12. f the Stake Post is kept in close contact with the side rail With shim plates handy select the combination necessary in order to shim outward to the side rail by an amount equal to or slightly greater than the measurement recorded above For example if the measurement in Figure 4 above was either a 5 16 or b 3 8 use one 1 4 thick and one 1 8 thick shim to cover a 3 8 distance for either scenario a or b Record the plates required for your application here by thickness Plate 1 ____ thick Plate 2 thick Plate 3 ___ thick or ALL circle if yes Again disassemble both bolt washer nut sets and place the required shim plates as determined above between the Channel and Stake Post components making sure that all shim plate bolt holes align with the corresponding bolt holes in the Channel and Stake Post 4 Insert the shaft of each carriage bolt through the holes in the Bridge Adapter s channel portion then through the selected shim plates and finally through the Stake Post Place a flat washer over the threaded end of each bolt followed by a hex nut Using the torque wrench Secure each bolt by torquing both sets to 60 Ibs ft 5 As in Step 2 above take a Socket Rod and slide into and through the hole slots visually verifying that the rod has been inserted as far as possible to a depth consistent with that of the Socket Rod installed with the driver s side Bridge Adapter as illustrated in Figure 5
13. g components removed go to the curb side of the trailer and starting from the back work your way to the foremost unit removing Load Binder and chains per Step 1 Finally ascend to the lower deck platform and remove each Bridge Adapter unit from its installed location one Leveler at a time by first removing the Socket Rod and then working the unit away from the Ramp Leveler s end adapter and out of the side rail stake pocket Now that you have uninstalled your Ramp Levelers you must immediately proceed to the Storage_ procedure below Storage You may store your Ramps in one of two methods 1 by grouping together near the lower to upper deck drop wall and securing to the deck with Ratchet Straps or 2 by using Sturdy Lite Ramp Storage Rack sets sold separately 1 method Supplies needed Qty 1 per Ramp Leveler Ratchet Strap labeled with a working load limit spec 1 2 3 4 to meet exceed DOT regulations 18 or longer supplied with Trailer or bought separately After bundling and storing the chain Clevis Load Binder set dunnage timbers and Bridge Adapters from each Ramp Leveler unit while standing on the lower deck take the foremost Ramp Leveler and place as close as possible to the drop deck wall at the front of the lower deck setting it on its bottom side Then take a Ratchet Strap and with one end hooked or spooled to an anchor point on one side of the Trailer and run one end over the top of the ramp a
14. in tolerances of this Regulation consistent with the installation and usage instructions of this Manual gt Improper installation of a Ramp Leveler may result in insecure trailer cargo which can result in serious property damage personal injury and or death If the procedures described within this Manual cannot be followed at any time you the end user are responsible for ceasing use of Ramp Levelers until such procedures can be resumed gt You must exercise caution at all times when installing using uninstalling and storing Ramp Levelers per the procedures described in this Manual If at any point during a procedure in this Manual you are unable to continue unassisted it is your responsibility to discontinue the procedure and seek assistance from a qualified person or persons Upon initial possession and before amp after each set of cargo hauled by using Ramp Levelers as installed per this Manual you must visually inspect each Ramp Leveler assembly along all visible surfaces and all weld junctions for any signs of material yielding i e bent deformed metal and or failure i e cracking tearing of material If you observe any yielding and or failure whatsoever you must avoid using the Ramp Leveler assembly indefinitely and contact Sturdy Lite or a local distributor to inquire about a new unit Pre Install Application Survey Supplies needed 1 2 3 Qty 1 tape measure 25 or longer Qty 1 electronic
15. ioning the cargo s distance length wise along the upper deck and or changing the location of the rearmost Ramp Leveler If you cannot come to a definitive conclusion on the manner of resolving this issue for your setup configuration please contact the distributor from whom you purchased your Ramps and or Conversion Kit for consultation Since many Trailers have irregular pocket spacing near the extremities of the lower deck s length span the foremost pocket on the lower deck side rail to the drop deck wall must be considered for final designation of the specific pockets to be used for installing Ramp Levelers per the following a Starting from the driver s side of the Trailer measure the distance in inches from the drop deck wall to the center line of the foremost lower deck side rail pocket as illustrated in Figure 3 below Figure 3 Measuring the distance from the drop deck wall to the center line of the foremost lower deck side rail pocket Record as Foremost Stake Pocket Distance FSPD in Now after reading scenarios b 1 b 2 below you will determine the location of the first pocket In either you will mark each pocket designated for use by tying a piece of rope string around one side of the pocket b 1 If the value of FSPD is less than nine 9 inches you will install the foremost Ramp Leveler in the pocket location equal to the Effective Spacing value as measured from the foremost pocket s center line in effect
16. rough slotted bar amp wrapped around immediate segment 12 Take the loose end of this chain and with one Load Binder at hand insert either Clevis hook tip from the Load Binder into the last chain link 13 Take a second chain piece from the opened chain hook set package and insert the tip of the other Clevis hook from the Load Binder into the last link on one end of the chain Then take another Clevis hook from the package and secure it through the last chain link on the other end of this chain 14 While holding the Load Binder up with one hand take the just secured Clevis hook on the chain into your other hand and run it down into the side rail stake pocket on the same side which the Ramp Leveler Stake Post s slotted bar is oriented to adjacent to the pocket which the Post is set into Once you have taken the hook amp chain through the bottom opening of the pocket as far as the chain s length allows take the hook in hand and bring it up along the outside area near this pocket and loop this remaining free segment of the hooked end of the chain over the segment of the chain hooked into the Load Binder 15 Similar to Step 11 wrap the remaining segment of the hooked end chain around the segment hooked to the Load Binder circling several times and inserting the Clevis hook s end into the nearest chain link available on the Binder hooked segment The results of Steps 10 through 15 here should look similar to that illustrated in Figure 8
17. s for a 27 TDH you will again need two 2 4x4 timbers as well as one 1 4x6 aluminum tube shim provided by Sturdy Lite along with custom Bridge Adapters If TDH is not within 1 of each Ramp Leveler s overall height then you must avoid using any Ramp Leveler s in possession and obtain correct units Measure the total length of upper deck distance available for use with your cargo as depicted in Figure 2 below shown with the entire upper deck length available Figure 2 Measuring the Trailer s upper deck length available for use entire deck shown available in this view 4 Record as Upper Deck Length UDL ft You must ensure that your hauling situation provides for this value to be at least eight feet as this Manual s application logic does not provide for using Ramp Levelers to haul cargo without such a substantial portion of the Trailer s upper deck for front end cargo support 5 Measure or obtain from the cargo supplier the overall length of the cargo which you plan to haul Record here as Cargo Length CL ft 6 Using the calculator subtract UDL from CL and record here CL UDL ft You will refer to this value in the next step 7 Using the values obtained for TCW and CL UDD in steps 1 and 6 above respectively use the following table to determine the number of Ramp Levelers which are required for your hauling conditions Table 1 Number of Ramp Levelers required N as determine
18. transportation must verify that the integrity of each item involved in transport meets or exceeds the proper regulatory specifications As mentioned in Step 2 of the Survey Section and Step 8 of the Installation Section of this Manual under no circumstances whatsoever are you to use more than two 2 4x4 dunnage timbers in the to channel of any Ramp Leveler If you cannot meet the aforementioned requirement you must avoid use of your Ramp Levelers until replacement unit s which satisfy this requirement can be obtained Maintenance Ramp Levelers are to be inspected per the directive specified in the Warning Notice listed in the Important Safety Notices section and stored per the Storage Procedure described in the following section of this Manual 14 Uninstall amp Storage Procedures Uninstall 1 2 3 4 5 After completely unloading all cargo hauled using Ramp Levelers starting from the front end of the driver s side of the trailer go to the foremost unit disengage the Load Binder ratchet lock and remove its Clevis hooks from the chains Then remove each chain from its anchor point as mentioned in Steps 11 through 15 of the Installation Section above Next remove the dunnage timbers from the Ramp Leveler s Timber Tabs Go to each additional Ramp Leveler unit beyond the foremost and repeat the Load Binder amp chains removal process as in Step 1 Once all units have had their driver s side anchorin
19. ve a finished Ramp Leveler height within 1 of the Total Drop Height you must avoid use of your Ramp Leveler s until replacement unit s which satisfy this requirement can be obtained 9 While you remain on the lower deck platform repeat Steps 1 through 6 above for each additional Ramp Leveler as required Once all other Ramp Levelers have been placed per this process you may return to the ground level 10 Gathering all required Load Binders and sets of 5 16 chain and Clevis hook start from the driver s side of the Trailer s lower deck front boundary and go to the first Ramp Leveler 11 Take the 24 length of 5 16 chain and one Clevis hook from the first set and secure the Clevis hook through the last chain link on either end Then lower this hooked end down into and through the side rail stake pocket forward of the first Ramp Leveler and bring back up along the outside surface of the pocket 11 forming a loop in the chain and securing the Clevis loop in a chain link such that the loop has minimal slack 12 Take the loose end of this chain and with one Load Binder at hand insert either Clevis hook tip from the Load Binder into the last chain link 13 Take the 48 length of chain from the opened chain hook set and insert the tip of the Load Binder s other Clevis hook into the last link on one end of the chain Then take another Clevis hook from the package and secure it through the last chain link on the other en
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