WORKMASTER TO-A02 User manual

TO-A02
Trailer Trap Opener
OWNER / OPERATOR MANUAL

PH: 866.476.9217
WORKMASTER disclaims any liability for injuries, death or damages arising directly or
indirectly, from the use, operation or application of this product not in accordance with
the procedures, specifications and recommendations contained in this owner’s manual.
The user of this product is responsible to install, maintain and operate the product and
parts or components manufactured or supplied by WORKMASTER in such a manner as
to comply with all federal, state and local rules, ordinances, regulations and laws,
including the Williams-Steiger Occupational Safety Act, and the American National
Standards Institute Safety Code.

PH: 866.476.9217
SYMBOLS
The following symbols are found throughout this Operator's Guide to alert the reader to
the relative danger that may result from non-observance.
This indicates a situation in which a hazard is
imminent and will result in a high probability of serious
injury or death.
This indicates a potentially hazardous situation, which
could result in minor to moderate injury.
CAUTION
This indicates a potentially hazardous situation or
unsafe practice which could result in product or
property damaged.
IMPORTANT
This symbol indicates a general statement to assist the
user in the operation or maintenance of the
equipment.

PH: 866.476.9217
TABLE OF CONTENTS
SECTION PAGE
I. Introduction 1
II. Safety 2
III. Required Materials 5
IV. Pre-Start Checklist 6
V. Assembly 9
VI. Operation 10
VII. Storing Your TO-A02 Trap Opener 12
Figure 1 Trailer Type Drive Fittings 6
Figure 2 TO-A02 Opener Kit 8
Figure 3 Forward / Reverse Trigger 10
Figure 4 Dimension Template C-1
Appendix A Air Preparation Kit A-1
Appendix B Parts List B-1-4
Appendix C Technical Specifications & Dimensions C-1
Appendix D Calibration Chart D-1

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I. INTRODUCTION
Fast, safe and economical unloading of bulk trailers continues to be a problem at most
unloading sites. One of the biggest contributors to this problem is the often time-
consuming and difficult manual job of opening and closing traps or gates of these
trailers. Unloading speed, weather conditions, age, abuse, corroded traps or load
compaction can combine to prevent gate mechanisms from operating smoothly.
Regardless of cause, the costs associated with the problem are significant. Delays in
emptying the trailers means slow turnaround, increased costs, and interrupted
production schedules. Even more importantly, the chance of worker injury is high since
at many unloading sites, repetitive stress injuries to worker’s shoulders, arms, wrists,
and backs caused by hand-cranking traps is a common occurrence.
To meet our commitment of “WE FIND A WAY – OR MAKE ONE
®
”, WORKMASTER
has developed a line of Trailer Trap Openers and accessories which provide a safe,
efficient and economical solution to the problem of rapidly opening and closing traps at
a busy unloading site. There are portable and stationary electric and pneumatic units
available to eliminate the need for hand cranks, trap retrofit kits or other methods
sometimes used on this difficult job.
This Owner/Operator Manual details the specifications, operation, maintenance and safe
use of the TO-A02 Pneumatic Trailer Trap Opener. Experience has shown that the
TO-A02 Opener will rapidly and safely open any trap. However, the same experience
demonstrates that total satisfaction in use depends on attention to detail in operating
and maintaining the unit
IMPORTANT
All persons involved in the operation and maintenance
of this equipment should be thoroughly familiar with
the contents of this manual.

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II. SAFETY
Safety must be considered a basic factor in machinery operation at all times. All rotating
products are potentially dangerous. Most accidents are the result of carelessness or
negligence.
It is the responsibility of the owner and operator to install, maintain, and operate the
parts or components manufactured and supplied by WORKMASTER, in such a manner
as to comply with the Williams-Steiger Occupational Safety Act and with all state and
local laws, ordinances, regulations, and the American National Standards Institute
Safety Code (ANSI).
To prevent injury to yourself or others, and/or damage to equipment, you should
adhere to the following basic safety instructions.
1. Read carefully the entire Manual prior to installing or operating equipment.
2. Always follow proper precautions and use proper tools and safety equipment.
3. Be sure to receive proper training.
4. Always use the equipment and all its components in applications for which
they are approved.
5. Be sure to assemble all components correctly.
6. Never use worn, defective or damaged components.
7. Practice good housekeeping at all times, and maintain good lighting around
all equipment.
8. Perform required Lock-out/Tag-out procedure on all energy sources to the
equipment, mounting structure, loading and discharge systems in accordance
with ANSI Standards before installation or maintenance.
Failure to observe the following warnings will result in
serious injury or death and in damage to equipment.

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9. Keep hands, loose clothing and long hair away from the Reaction Arm.
10. This Opener will exert a strong torque reaction force. Use proper mechanical
support and correct Reaction Arm positioning to control these forces.
11. Use only Drive Fitting Accessories recommended by WORKMASTER.
12. Do not carry the Tool by the hose.
13. Inspect, maintain, operate, and install the Opener in accordance with all
applicable standards and regulations (local, state, country, federal, etc)
14. Keep clear of whipping air hoses. Shut-off air supply before approaching a
whipping hose.
Do not use the Reaction Arm as a dead handle. Do not
position the Reaction Arm so that it tilts the Opener
off the axis of the Tra
p
’s Ca
p
stan.
CAUTION
Do NOT Exceed Maximum Regulator Pressure setting
for type of Trailer Trap being opened (Strap vs Rack &
Pinion). Damage will occur if excess PSI is used.
A whipping air hose could result in serious injury or
death.

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III. REQUIRED MATERIALS
The following items are not supplied with your WORKMASTER Trap Opener but are
necessary for its proper installation and operation.
CLEAN and DRY Compressed Air
High Quality Air Hose from the Compressor to the WORKMASTER supplied
FRL: 1/2" (for ≤25ʹ from supply) / 3/4" (for >25ʹ from supply); fitted with
1/2" MPT Nipple for connection to “IN” Port of supplied FRL
Fill the FRL’s Lubricator with supplied WORKMASTER Air Tool Oil

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IV. PRE-START CHECKLIST
1. Be sure all hoses and fittings are at least 1/2” ID and tightly secured.
2. Ensure an accessible emergency shut-off valve has been installed in the air
supply line and make others aware of its location.
3. To prevent hose whipping if a hose fails or a coupling disconnects, install a
properly sized safety air fuse upstream of the hose, and use a Whipcheck
®
anti-
whip device across any hose couplings without an internal shut-off.
4. Ensure the airline is not connected to the Tool before performing the following
steps.
5. Ensure the Reaction Arm is properly attached and secured to the splined section
of the Opener.
6. Select your desired Capstan Drive Fitting if other than the Standard shipped (on
the Tool).
7. Ensure the FRL has proper pneumatic tool oil for lubrication.
8. Torque depends on the air pressure exerted on the air motor under load.
Adjusting the FRL's Regulator Knob initially sets the torque. To decrease the
torque output, turn the Regulator Knob counterclockwise to lower the air
flow/pressure. All TO-A02 Openers are shipped and calibrated at 20-21 PSI
(approx) for 140 to 145 ft-lbf. See Appendix D: Calibration Chart
9. Check for the desired torque setting for the Make/Model Trap being opened
against the calculation chart. On the WORKMASTER FRL, adjust the air
pressure by using the Air Regulator Knob to set the desired pressure / torque.
With the TO-A02 not on the Capstan, press the trigger and adjust the Regulator
pressure at the same time.
CAUTION
Experience shows that a Regulator setting of 20
to 21 PSI (140 to 145 ft-lbf) is all that is
required to open Strap-type Trailer Traps. Rack
and Pinion type Trailer Traps may require a
Regulator setting of 30 to 40 PSI (244 to 250
ft- lbf
)
to o
p
en.

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Figure 1: Trailer Type Drive Fittings
The torque settings have to be considered only as a
guideline. Because of variations in pressure and/or air
flow, as well as other application issues, deviations
may be necessary. Due to the CFM required, when
the Opener is running at free speed, it may not be
possible to set the Regulator to the desired pressure
due to air pressure drop-off.
CAUTION

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For extreme cold weather, use approved cold weather
pneumatic tool lubrication to prevent freeze ups.
IMPORTANT
Do not fold or bend the supply hose excessively, and
check all hoses for damage before use. A damaged
hose must not be used, as there is a risk of a hose
burst. This may lead to a wildly whipping hose with a
risk of personal injury. Also, check the air fitting and
connections for tightness or damage.

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V. ASSEMBLY
The TO-A02 comes assembled and ready to use. Follow the steps below
to connect Airline and verify pressure setting on the supplied FRL Unit.
1. Verify you are familiar with each of the supplied Items as shown in
Figure 2: TO-A02 Opener Kit
Figure 2: TO-A02 Opener Kit
ITEM P/N DESCRIPTION
1 32-70800 Torque Tool
2 32-70802 Multi-Position Side
Handle
3 33-10060 1-1/2" Drive Fitting w/
Torque Reaction Arm
4 33-10056 1" Cornhusker Drive
Fitting Adapter w/
Extended Torque
Reaction Arm
5 33-10050 1" Slotted Pin Drive
Fitting Adapter
6 32-70801 Air Supply Kit
7 32-70806 10' Fitted Hose Assy
8 36-21010 Air Motor Oil
9 32-90020 Utility Bag
1 2 8
3
4 5
6 7 9

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VI. OPERATION
1. Place your TO-A02 Drive Fitting completely into/over the Trailer Trap to be
opened or closed.
2. Ensure the torque reaction area of movement is taken up by the Reaction Arm.
Also, ensure the Reaction Arm is stable and will support counter torque.
3. Hold the TO-A02 perpendicular to the Trap's Capstan for the complete duration
of the rotation process to open or close the Trap.
IMPORTANT
Because of the high mechanical stress on the TO-A02
Opener, it is essential to provide the FRL Unit with
sufficient oil supply, to reduce the risk of damaging
the vanes of the air motor. Adjust the oil feed on the
FRL’s Lubricator to 2 to 3 drops per-minute for regular
equipment use.
CAUTION
Do NOT Exceed Maximum Regulator Pressure setting
for type of Trailer Trap being opened. Damage will
occur if excess PSI is used.
CAUTION
Experience shows that a Regulator setting of 20
to 21 PSI (140 to 145 ft-lbf force) is all that is
required to open Strap-type Trailer Traps. Rack
and Pinion type Trailer Traps may require a
Regulator setting of 30 to 40 PSI (244 to 250
ft- lb
f
force
)
to o
p
en.

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4. After pressing the trigger on the pistol grip to open the Trap, the TO-A02 will
rotate until it becomes torqued, the tool will then stall out.
5. The trigger will then need to be depressed in the opposite direction to release
the counter torque load off the Reaction Arm. Once this is done, you can then
remove the Opener and Drive Fitting from the Trap's Capstan and move on to
the next Trap.
Figure 3: Forward / Reverse Trigger
Power tools can vibrate in use. Vibration, repetitive
motions or uncomfortable work positions may be
harmful to your hands and arms. Stop using any Tool
if discomfort, tingling feeling or pain occurs. Seek
medical advice before resuming.
Keep your body stance balanced and firm. Do not
overreach when operating this Tool. Anticipate and be
alert for sudden changes in motion, reaction torques,
or forces during start-up and operation.
CW: Clockwise Rotation
CCW: Counter-Clockwise Rotation

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6. When closing a Trap, the Tool will continue to rotate until the Trap is closed.
7. Continue the process for opening or closing each Trap.
IMPORTANT
After extended use of the Opener, the air pressure
setting should be re-checked and may require a minor
adjustment. This is usually caused by variations in the
air supply providing airflow to the FRL Unit, or due to
weather conditions.
CAUTION
Add, if necessary, the appropriate Drive Fitting Adaptor
for the next Trap as shown in Figure 1: Trailer Type
Drive Fittings, P6 . Ensure the Standard Drive Fitting is
properly secured to the Tool's square drive with the
locking pin and safety securing o-ring.

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VII. STORING YOUR TO-A02 TRAP OPENER
1. Shut-off the pressurized air to the FRL by turning off the air to the FRL Unit.
2. Bleed-off the stored air in Tool and hoses by depressing the trigger switch in
either direction.
3. Disconnect the supply hose from the FRL Unit, and disconnect the air hose at the
TO-A02 Opener.
4. If the TO-A02 Opener is not to be used for an extended period of time, spray
pneumatic lubricating oil into the TO-A02's Inlet Fitting. Reconnect the air hose
and supply hose to the FRL Unit's air inlet fitting. Cycle the FRL unit momentarily
to ensure that 2-3 drops of lubricating oil has entered into the Tool's air motor.
Then stop and shut-off the system as previously stated above in steps 1, 2, 3.
5. Store your TO-A02 Opener and all components and accessories in the storage
bag that it was shipped in.
IMPORTANT
Repairs should be made only by authorized personnel.
Consult AIRMATIC, WORKMASTER’s Authorized
Service Center. The use of other than genuine
WORKMASTER replacement parts may result in
safety hazards, decreased tool performance, increased
maintenance, and may invalidate all warranties.

A-1
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APPENDIX A. AIR PREPARATION KIT
32-70801 Filter, Regulator, Lubricator and Fitted Hose Assembly
ITEM QTY PART # DESCRIPTION
1 1 WM-FRL-001 Precision Regulator
2 1 WM-FRL-001-K Knob for Precision Regulator
3 1 WM-FRL-002 Lubricator Unit
4 1 WM-FRL-002-B Bowl Assembly for Lubricator Unit
5 1 WM-FRL-002-SG Sight Glass for Lubricator Unit
6 1 WM-FRL-003 Filter with Auto Drain
7 1 WM-FRL-003-B Bowl Assembly for Filter w/ Auto Drain
8 1 WM-FRL-003-F Filter Element
9 2 WM-FRL-004 Mounting Brackets
10 1 WM-FRL-005 Yellow Roll Cage
11 1 WM-FRL-007 Pressure Gauge
12 1 32-70806 10’ Hose Assembly
13 1 WM-FRL-010 1/2” Hose Barb to Female Coupler
     
Filter separates water &
contaminants.
Regulator allows accurate
setting of output torque.
Lubricator provides oil to Tool's
Air Motor.
(TOOL)
(IN)
(OUT)

B-1
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APPENDIX B. PARTS LIST
DRIVE ASSEMBLY
ITEM QTY. PART # DESCRIPTION
1 1 WM-AM19-ASSY HANDLE AND MOTOR ASSEMBLY
2 1 WM-AM19-41 AIR MOTOR BALL RETAINER
3 35 WM-CM-BB STEEL BALL
4 3 WM-05-ST-G SPUR GEAR
5 1 WM-05-ST1 1
st
STAGE GEAR CAGE
6 3 WM-ST-GW SPUR GEAR
7 1 WM-05-ST2 2
nd
STAGE GEAR CAGE
8 1 WM-05-HSA HIGH SPEED ANNULUS
9 2 WM-05-DOWEL LONG HARDENED DOWEL
10 2 WM-05-TW THRUST WASHER
11 1 WM-05-NRB NEEDLE ROLLER THRUST BEARING
12 1 WM-05-DTSA DRIVE STAGE ASSEMBLY
13 1 WM-05-MB MAIN BEARING
14 1 WM-CM-OR-MA MAIN ANNULUS O-RING
15 1 WM-05-OR-DA DRIVE ANNULUS O-RING
16 4 WM-CM-SS-DA DRIVE ANNULUS SET SCREW
17 1 WM-05-DA DRIVE ANNULUS

B-2
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APPENDIX B. PARTS LIST
HANDLE & MOTOR ASSEMBLY
ITEM QTY PART # DESCRIPTION
1 1 WM-AM19-01 HANDLE HOUSING
2 1 WM-AM19-03 GASKET
3 1 WM-AM19-11-1 MOTOR ASSEMBLY
4 1 WM-AM19-21 BACKHEAD SPACER
5 1 WM-AM19-23 BACKHEAD
6 1 WM-AM19-25 TRIGGER
7 2 WM-AM19-27 SNAP RING
8 2 WM-AM19-29 POPPET VALVE ASSEMBLY
9 1 WM-AM19-33 INLET BUSHING O-RING
10 1 WM-AM19-35 INLET BUSHING
11 1 WM-AM19-37 INLET BUSHING CAP SCREW
12 1 WM-AM19-35-1 INLET BUSHING MUFFLER ELEMENT
13 1 WM-AM19-41 BALL RETAINER
14 1 WM-AM19-43 DOWEL PIN
\


B-3
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APPENDIX B. PARTS LIST
AIR MOTOR ASSEMBLY
ITEM QTY PART # DESCRIPTION
1 1 WM-AM19-05 FRONT BEARING
2 1 WM-AM19-07 FRONT END PLATE
3 1 WM-AM19-09 DOWEL
4 1 WM-AM19-11 MOTOR HOUSING
5 6 WM-AM19-13 VANES
6 1 WM-AM19-15 ROTOR
7 1 WM-AM19-17 BACK END PLATE
8 1 WM-AM19-19 BACK BEARING