INSTALLATION INSTRUCTIONS

Transcription

1 INSTALLATION INSTRUCTIONS Thank you for purchasing an AUTOLOCK Electric Tarp. ACI proudly manufactured this product using superior quality materials and workmanship. With proper care, your tarp will provide years of service and enjoyment. NOTICE TO INSTALLER: Even if familiar with product, read instructions prior to installation as improvements may be made without notice. Always handle components with care. If you have questions or problems, have serial number ready and call customer service. When done, these instructions must be given to the consumer. NOTICE TO CONSUMER: Before using this product, read operating, maintenance and safety sections. Save these instructions for future reference. FOR YOUR RECORDS DATE PURCHASED: WHERE PURCHASED: SERIAL NUMBER: (Located at rear of tarp on stationary tube side) Questions? (800) agricover.com

2 TABLE OF CONTENTS OPERATING INSTRUCTIONS 3 INSPECTION AND MAINTENANCE 4 PREPARATION/TOOLS 5 INSTALLATION INSTRUCTIONS 6-48 ROCKER SWITCH WIRE SCHEMATIC DIAGRAM 49 WARRANTY Back Cover! SAFETY INFORMATION Always use adequate caution when operating tarp. Make sure tarp is open before unloading or loading. Make sure nobody is on or near tarping system before and during operation. Do not operate tarp with box hoisted in an elevated position. If tarp is covered with snow, remove before operating. End caps must be free from grain that may be piled on them. Grain should not be heaped higher than end caps. Do not operate this vehicle at highway speeds, while tarp system is in the open position. Instruct everyone who will operate this tarp on the proper procedures, or have them read this entire manual. 2

3 ELECTRIC MOTOR OPERATING INSTRUCTIONS NOTE: For kits with a tarp control box, refer to the tarp control box manual for operating instructions. 1. CLOSING TARP FROM OPEN POSITION Turn switch to the CLOSED position and hold. Visually view tarp position and release switch when tarp is fully closed. Fully closed is when tarp roll tube is tight up under latch plate. 2. OPENING TARP FROM CLOSED POSITION Turn switch to the OPEN position and hold. Visually view tarp position and release switch when tarp is fully open. Fully open is when tarp roll touches tarp stops. TOO TIGHT in open position could cause damage to tarp stops, tubes and tarp. circuit breaker. Holding switch until circuit breaker trips is too long. When this occurs, breaker will trip and reset if the breaker is overloaded by the motor. To reduce unnecessary strain on components, always release switch before breaker trips. If breaker trips and does not reset, it may have detected a continuous short and will not reset until the short is repaired.! STAINLESS STEEL KIT ONLY CAUTION: To avoid galling of stainless steel hardware, use anti-galling spray, grease or lubricant on threads and avoid high speed when fastening. Do not use impact tools for stainless steel hardware. A) 5/16 x 1 stainless steel bolts, nuts and washers: Use these for bolting end cap to end cap bracket. B) 3/8 x 1 stainless steel bolts, nuts and washers: Use these when bolting the following parts to box wall: end caps, end cap brackets, tarp stop brackets, latch plate, cord corner guides, handle holder or pivot arm mount. When possible, use nuts and washers with these bolts. C) 3/8 x 1 non-stainless steel self threading bolts: Use these to cut threads into 5/16 holes in area where you cannot get at to turn nuts on. Drill 5/16 hole. Turn 3/8 x 1 self threading bolt in hole to cut threads, then turn it back out. Turn 3/8 x 1 stainless steel bolt in for attachment. 3

4 ! INSPECTION AND MAINTENANCE Periodic preventive maintenance should be practiced. Inspect tarp and hardware for abrasions or loosened bolts that may need adjustment and/or repair and adjust tension when needed. Tarp must be kept to a recommended tension setting equally on both ends, or excessive tarp wear may occur. tarp does not pass this simple inspection, make all appropriate repairs or adjustments immediately before serious damage occurs. Always use genuine Agri-Cover, Inc. replacement parts if repairs are needed. Periodically check the tightness of mounting bolts and electrical connections, remove any dirt or corrosion that may have accumulated on the electrical connections. Inspect front and rear drive line for wear. Replace as needed. The motor gearbox is lubricated with 5 ounces of Mobil SHC 630 lubricant and sealed for life. chain inside of gear box. Grease Zerk Chain Lube 80W SAE Gear Oil 4

5 TOOLS NEEDED 1. Protective eyewear 2. Marking pencil 4. Lock pliers 5. Drill with 1/8, 3/16, 5/16, 3/8 and 1/16 drill bits, #3 Phillips driver bit 6. Tape measure 7. Impact wrench with 9/16 socket 8. Two 1/2 and 9/16 wrenches, a 7/16 and 3/8 wrench IMPORTANT NOTES: PREPARATION 9. Hammer 10. Heat gun 11. #25 torx driver 12. Torque wrench (inch-lbs.) 13. 7/32 Allen wrench 14. Wire cutter, crimper and stripper 15. Utility knife 16. Electrical tape The truck or trailer on which installation is being done must be parked on a level surface. This prevents box from twisting, which can cause a poor installation. Box must be square and straight, center must not be pulled together or spread apart. Make adjustments prior to installation. Inspect box for sharp edges or points that make contact with tarp and/or cables, remove or grind smooth. It may be necessary to remove or reposition ladders or other devices that manufacturer. If you have an extension on top of your box, make sure it is secure by bolting in place. Most fasteners used in this installation are 3/8 x 1 self threading bolts. A 5/16 hole must be drilled to obtain correct tap drill hole size. Attach these bolts only to secure structures on box. In some cases it will be necessary to use washer and nuts or other types of fasteners (NOT FURNISHED) to ensure a solid anchor. Before you begin, measure the outer length and width of your box. Also measure the length of the tarp and the width of the end caps to ensure you have received the correct size. The tarp must measure between 8 and 16 shorter than the box length. The end caps must be at least 1 narrower than box width, usually 1 to 3 narrower. NOTE: Some systems may require end cap variations which will result in short outer tarp lengths. 5

6 INSTALLATION INSTRUCTIONS 1. END CAP WEATHER SEAL NOTE: For best adhesion, air and surface temperature should be above 60 F. A. WEATHER SEAL Clean underside of cap before adhering weather seal. Repeat on each end of front and rear end cap. Factory installed edge guard End cap 1) Align weather seal as shown. Test needed for optimum seal. Align weather seal Approx. 1/2 Edge guard Weather seal 2) Adhere weather seal at both ends of end cap. NOTE: Before adhering weather box. Sometimes caps may need to be trim cut for special situations (See Figure 2A and installation tip on page 9). Tarp Push end cap down tight against top of box. 3) Push down on end cap to compress seal and hold. Then proceed to next step for end cap installation. IMPORTANT: Sharp edges cause tarp damage not covered by warranty. Make sure ends of end caps are installed tight to box. Always inspect areas where tarp closes around end cap and top corner of box and make required adjustments to avoid tarp damage. 6

7 2. FRONT AND REAR END CAPS NOTE: For stainless steel kits see page 3 for bolting procedures A. FRONT END CAP box, drill 5/16 holes in box wall at each factory hole in end cap. Fasten with 3/8 x 1 self threading bolts. CAUTION: DO NOT STAND OR WALK ON END CAP Maintain equal dimensions on both sides Front end cap Cap must be shorter than box 1/2 min. 1-1/2 max. 3/8 x 1 self threading bolts at each hole in end cap FIGURE 2A TIP: notching overhang, removing protruding objects from box, or by trim cutting end caps shorter if too wide for box. Both front and rear end caps should measure at least 1/2 narrower than top of box. 7

8 2. FRONT AND REAR END CAPS (continued) NOTE: For stainless steel kits see page 3 for bolting procedures B. END CAP BRACKETS Center end cap brackets underneath sealing rib of end cap and butt up against inside of box. Mark center locations of slotted holes. Drill 5/16 holes and use 3/8 x 1 self threading bolts to secure bracket to inside of box. Next, drill 5/16 holes in center of slotted holes through end cap. Make sure cap is and nut. Sealing rib in end cap (do not place a bow here) Tilt up 1/4 at center 5/16 x 1 bolts, washers and nuts 3/8 x 1 self threading bolts turned into 5/16 tap hole End cap bracket (inside of box) 2 per end cap SIDE VIEW OF FRONT END CAP FIGURE 2B TIP: Some kits require non-standard end caps. These kits will have 2 front style side mount end caps. Skip rear end cap instructions and follow front end cap instructions for end cap at rear of box. 8

9 2. FRONT AND REAR END CAPS (continued) NOTE: For stainless steel kits see page 3 for bolting procedures C. REAR END CAP Center top mount style rear end cap on back of box. Position end cap to overhang back of box by 1/4. Mark deepest location at each slotted hole on top of box at rear of end cap. After marks are made remove end cap, drill 5/16 holes at these locations. Turn 3/8 x 1 self threading bolts halfway tightening bolts. Install end cap bracket in similar manner as front end cap. Tilt up 1/4 at center Sealing rib in end cap (do not place a bow here) End cap bracket lock washers and nuts 3/8 x 1 self threading bolts turned into 5/16 tap hole All self threading bolts shown partially turned in to allow end cap slots to slide under bolt head, 1/4 overhang at rear of box FIGURE 2C TIP: If box has uneven layer of metal at top where end cap mounts, apply adhesive seal tape and shim with washers (not included with kit) under end cap at each bolt. Washer shim at each bolt location sealing tape Extra layer of metal 9

10 3. BOW POCKETS & BOWS NOTE: Bows supplied in this kit are not designed to hold box together. Leave all existing bows, braces or chains in place. A. BOW POCKETS/BOW EXTENSION be placed 30 in from rear of box. Position remaining bows evenly spaced (See Figure 3D for bow placement). Attach bow washer, lock washer and nut. Nut Lock washer Flat washer Bow extension Box rail Bow pocket Drill 5/16 holes in box rail, turn self threading bolts into holes - insert bow & extension - then tighten bolts FIGURE 3A 10

11 3. BOW POCKETS & BOWS (continued) NOTE: For stainless steel kits see page 3 for bolting procedures B. STAINLESS STEEL KIT - TOP MOUNT OPTION This stainless steel kit comes with bows and bow extensions that bolt to the top of the box rail. Drill 5/16 hole 1/2 from outer edge. Use 3/8 x 1 self threading bolt to cut threads for 3/8 x 1 stainless steel bolt. When possible, Stainless steel bolt Deburr any sharp edges that may contact tarp here and at other end of bow Box rail 1/2 from outer edge FIGURE 3B 11

12 3. BOW POCKETS & BOWS (continued) C. STAINLESS STEEL KIT - SIDE MOUNT OPTION each location and use 3/8 x 1 self threading bolt to cut threads for 3/8 x washer, lock washer and nuts. Stainless steel lock washer Bow extension Stainless steel nut Stainless steel Box rail Stainless steel bolt FIGURE 3C 12

13 3. BOW POCKETS & BOWS (continued) D. BOWS each end of bow into bow pocket. Center bow in an upright position. Adjust bow to set 1 higher than end cap. Drill 5/16 hole through end of bow and in extension. Drill hole so bolt head will not rub tarp. Turn 3/8 x 1 self threading bolt into bow assembly. IMPORTANT: Purpose of bolt is to hold bow rigid at properly set height. TIP: First, set front and rear bows to correct height. Install ridge strap on top of bows and draw tight until no slack. Adjust remaining bows to just touch bottom of ridge strap. * Example: If - 2 bows are left, divide by 3 for 3 equal spaces If - 4 bows are left, divide by 5 for 5 equal spaces Standard two center First bow at front Optional one ridge strap in center Last bow at rear * Divide remaining space by number of bows left plus one Warning: All bows must be used Clamp lock pliers on bow extension to hold bow in place 1 With bow inserted in bow pocket and adjusted to set 1 higher than end caps - drill 5/16 hole 1 from end of bow and secure with self threading bolt. FIGURE 3D 13

14 4. RIDGE STRAPS A. RIDGE STRAP Attach hook end of strap to hole in center of front end cap. If installing two Attach ratchet end of strap to rear end cap. Draw strap tight. DO NOT OVER TIGHTEN. Trim cut extra strap to about 8. TIP: Twisting the ridge strap prior to attaching it to ratchet will help decrease the chance of strap. The number of twists needed depends on the length of the trailer, adjust accordingly. Make sure not to wind any twist in the ratchet. Front end cap Twist ridge strap at ratchet end Rear end cap Bow Trim cut excess ridge strap ALTERNATE RIDGE ROPE OPTION Attach hook end of rope to hole in center of front end cap. If installing two ratchet end of rope to rear end cap. Thread rope through ratchet as shown in Figure 4E, pull on loose end of rope to remove slack. Use ratchet until rope is tight with a minimum of 4 wraps. DO NOT OVER TIGHTEN. Trim cut extra rope to about 8 and tie a knot to prevent fraying. Rear end cap Ratchet Front end cap Bow Pull rope through loop to remove slack, knot end to prevent fraying Loop rope through ratchet FIGURE 4E 14

15 5. TARP STOPS NOTE: For stainless steel kits see page 3 for bolting procedures A. FRONT AND REAR QUICK RELEASE TARP STOP These brackets secure the stationary side of the tarp to the box. For normal roll applications, mount brackets on PASSENGER side of box. For reverse tarp stops (wide tarp stops with set screws) preferably 10 in from air dam on outside of box so top of bracket is 1/4 down from top of box. and last bracket. Align lower hole in tarp stop with lower hole in bracket. Assemble with clevis pin and bow tie pin. Leave bracket in open position for now. Clevis pins TIP: To remove bow tie pin, rotate 1/4 turn, then pull it out from clevis pin 1/4 10 from air dam Drill 5/16 holes and use (4) 3/8 x 1 self and last bracket Tarp stop base bracket Bow tie pins VIEW AT TOP FRONT CORNER OF BOX (passenger side) 15

16 5. TARP STOPS (continued) B. REMAINING QUICK RELEASE TARP STOP Position interior brackets evenly between front and rear tarp stops (See Example below) on outside of box so top of bracket is 1/4 down from top of box. Drill (2) 5/16 holes and use (2) 3/8 x 1 self threading bolts to mount interior brackets. Align lower hole in tarp stop with lower hole in bracket. Assemble with clevis pin and bow tie pin. Leave bracket in open position for now. EXAMPLE: If - 2 quick release brackets are left, divide by 3 for 3 equal spaces. If - 3 quick release brackets are left, divide by 4 for 4 equal spaces. If - 4 quick release brackets are left, divide by 5 for 5 equal spaces. Clevis pins *Divide remaining spaces by number of brackets left plus one 1/4 Bow tie pins Use (2) 3/8 x 1 self threading bolts for all interior brackets bracket Use (2) 3/8 x 1 self threading bolts with lock washer and nuts OPTIONAL OFFSET BASE BRACKET Tarp stop bracket Drill 5/16 holes and use (2) 3/8 x 1 self threading bolts with lock washer and nuts 16

17 6. LATCH PLATE A. POSITION LATCH PLATE Mount latch plate on side of box opposite from tarp stop brackets 0 to 3 down from top of box rail. Start 4-1/4 back from face of front end cap and stop 4-1/4 in from face of rear end cap. Trim if necessary (See Figure 6A & 6B). NOTE: On some boxes, latch plate may have to be moved up due to interference with hinges, swinging rear doors or the design of the top rail. TIP: Use C-clamp to hold latch plate in proper position for drilling holes and bolting. Latch plate mounted opposite side of tarp stop brackets. Start 4-1/4 in from face of front end face of rear end cap. Trim if necessary. FIGURE 6A 17

18 6. LATCH PLATE (continued) NOTE: For stainless steel kits see page 3 for bolting procedures B. BOLTING LATCH PLATE Use small groove line on latch plate as center point to drill 5/16 holes and and joints, second bolt 12 in from ends and joints and remaining bolts spaced 24 apart. Face of end cap Round corner of box Starting edge of latch plate 4-1/4 Drill 5/16 hole centered on groove (typical) Top of box from ends and joints Preferably 0 to 3 1-1/2 Typical Typical of all remaining bolt locations 4-1/4 Start latch plate 4-1/4 in from face of air dam face of rear end cap. Trim if necessary FIGURE 6B 18

19 7. ROLL TUBE / STATIONARY TUBE SPLICE A. SPLICING ROLL TUBES Kits with multiple roll tubes come with splice tubes. Check roll tubes for drilled holes with an aluminum weld (See Figure 7A). Slide second roll tube onto opposite end of splice until tubes are tight against each other. NOTE: Rope channels need to be aligned. Secure second roll tube by plugging each of the 4 factory drilled holes with (See Figure 7B). Roll tube Splice welded in roll tube Splice Roll tube Plug holes with aluminum weld (both sides) Plug holes with aluminum weld (both sides) FIGURE 7A FIGURE 7B ALTERNATE METHOD OF CONNECTION This method will replace welding in this step. With splice centered between roll tubes and rope channels aligned, drill pilot hole into splice through center of factory drilled holes using a 1/8 bit. IMPORTANT: Pilot hole needs to be centered in holes on roll tube. This will ensure screw heads will not touch sides of the factory drilled hole. Secure splice to each end of roll tube by turning (8) 1/4 x 3/4 self tapping screws into pilot holes (See Figure 7C). 1/4 x 3/4 self drilling Phillips head screw centered in each 5/8 factory drilled hole (both sides) FIGURE 7C 19

20 7. ROLL TUBE / STATIONARY TUBE SPLICE (continued) B. SPLICING STATIONARY TUBE 1 stationary tubes shipped in 2 pieces are spliced by inserting swaged end on one tube into standard size end of other tube. Assemble joint, align the tarp rivet holes at each end of the tube. Drill 7/32 hole through two layers of tube wall. Make sure rivet is fully seated and set with hammer. Tap each end plug into each end of stationary tube. End plug Before drilling, align tarp rivet holes with each other 3/16 drive rivet Drill 7/32 hole Insert swaged end inside standard end Press end plug into tube and tap in place with mallet 20

21 8. RIVET HOLES BEFORE attaching stationary tube and roll tube onto tarp, follow these instructions to mark and drill 1 rivet hole in each end of roll tube. A. MARKING AND DRILLING RIVET HOLES Align stationary tube with rivet holes, next to large roll tube without rivet holes as shown. Starting at rear of roll tube, use hole locations in stationary tube as guide and mark hole location to drill rivet holes in large roll tube as shown. Use 7/32 bit and drill hole where marked at each end of roll tube. NOTE: The tarp will need to be pulled tight, stretched approximately 1 to match rivet holes in tarp with rivet holes in tube (See step 9). FRONT END VIEW End view shows proper orientation of rivet, tarp and roll tube when assembled and hanging loose on side of box. Drive rivet Drill 7/32 hole here 5/8 Dashed line indicates position of tarp when attached to tube in later steps. Top side of tarp up. Drill 7/32 hole here 5/8 Roll tube FRONT Electric motor end driver side front In later steps, tarp will have holes here to align with holes being drilled FIGURE 8 8-1/2 7-1/2 Passenger side stationary tube 21

22 9. ATTACHING TUBES TO TARP TIP: The tarp is designed to be stretched to minimize wrinkling. A. ROLL TUBE edges and pocket facing down. Align front end of roll tube at rear on rope side of tarp. Refer to Figure 8 to identify front of roll tube. Align channel on roll tube with rope and slide tube onto tarp rope. Make certain rope is fully engaged in channel all along tube. TIP: Before sliding the roll tube onto the tarp rope, setting a doweltype roller under the middle of the roll tube will ease its assembly. Small stationary tube pocket Stationary tube Begin with front end of roll tube, thread rope into channel and slide tube onto tarp Rope Front end of tarp driver side FIGURE 9A 22

23 9. ATTACHING TUBES TO TARP (continued) B. ATTACHING ROLL TUBE At one end of roll tube align rivet hole in tarp with rivet hole in tube. Insert BLACK drive rivet into hole, making sure it is fully seated and set with hammer. At other end, pull tarp by hand to stretch it until holes on tube and tarp line up. Insert BLACK drive rivet into hole, making sure it is fully seated and set with hammer. C. ATTACHING STATIONARY TUBE Slide 1 stationary tube into small pocket of tarp. At one end align rivet hole in tarp with rivet hole in tube. Insert SILVER drive rivet into hole making sure it is fully seated and set with hammer. At other end, pull tarp by hand to stretch it until holes on tube and tarp line up. Insert SILVER drive rivet into hole, making sure it is fully seated and set with hammer. tube and then push rivet completely in. Silver drive rivet Black drive rivet Rope channel for rope to slide into the tube FIGURE 9B 23

24 10. SETTING ROLLED TARP ON BOX A. SETTING TARP ASSEMBLY Roll tarp assembly by hand to its open position, large tube to small tube. Have tarp stop clevis pins readily available for next sequence. Place rolled tarp up on top of side of box with tarp stop brackets. Center assembly from front to back of box. BE CAREFUL NOT TO LET TARP ROLL OFF BOX. Place small tube with tarp into brackets. Swing tarp stops up, align its holes with bracket holes and insert upper clevis pin. Repeat for all tall and short tarp stops. Insert all bow tie pins. This secures roll assembly to box. By hand unroll tarp to the other side of box and let tarp hang down in the closed position. Check to make sure tarp is still centered from front to back of box and make adjustments as needed. Quick release tarp stop Bow tie pins Tip: To remove bow tie pin, turn in 1/4 turn, then pull it out from TIP: clevis To remove pin. bow tie pin, rotate 1/4 turn, then pull it out from clevis pin Stationary tube shown locked in the quick release bracket with clevis pin Quick release base bracket 24

25 11. ROLLER GUIDES NOTE: For stainless steel kits see page 3 for bolting procedures Roller Flat washer Cotter pin Clevis pin Roller bracket A. ASSEMBLING ROLLER GUIDES side into the roller bracket. Line up holes and insert clevis pin through bracket, washers and roller. Secure clevis pin with a cotter pin. Repeat process for second roller bracket. NOTE: Stainless steel cotter pin should always be away from the tarp. Roller guide Cotter pin away from tarp Mark holes to drill Lowest point of roller above top of box 1/4 Drill 5/16 holes and secure with (2) 3/8 x 1 self threading bolts B. PLACING ROLLER GUIDE Position the roller guide 1/4 from cut end of latch plate. The lowest point of above the top surface of the trailer. Roller bracket should not interfere with end caps. Mark the best bracket holes for your application. C. SECURING ROLLER GUIDE Drill 5/16 holes at each mark and secure roller bracket with (2) 3/8 x 1 self threading bolts. For stainless steel kits, use self threading bolts to cut threads into 5/16 holes, then turn 3/8 x 1 stainless steel bolts with stainless steel washers and lock washers. Repeat step 11 for roller guide at rear of tarp. Always make sure cotter pin is away from tarp. 25

26 12. PREPARING TO INSTALL DRIVE LINES AND SPRING BOXES A. and set aside. Remove nut and bolt that holds spring to box. Set nut, bolt, and all contents aside for later. Inside is the drive line cord for next step. Complete spring box with covers on and hardware packed inside Spring inside Wear tube inside Untabbed cover removed and set aside Drive line cord removed from inside Hardware package removed from inside Tabbed cover removed and set aside 26

27 13. WRAPPING DRIVE LINE CORD ON ROLL TUBE Views shown are of roll tube at front of box. A. At front of box, tie loose overhand knot in one end of drive line cord. Insert loose knot into groove on roll tube. B. Slide knot over and pull tight. Wrap drive line cord around tube from outside going inward toward tarp, always toward box wall. C. Wrap drive line cord 12 full wraps and let excess hang down. Cord needs to be at least 1 away from tarp. 1 FRONT REAR Box Wall Box Wall Cord wrap Cord wrap 27 27

28 14A. MOUNTING SPRING BOX VERTICALLY NOTE: Determine orientation of spring box to be mounted either horizontally or vertically. If long spring box or horizontal, skip to step 14B. A. At front of trailer with roll tube hanging down, position spring box 5 to 14 down from roll tube clear of any interference and make mark at each end of spring box. B. Orient spring box so pulley bracket is closest to roller guide. Align center of spring box with center of roller guide. Drive line cord needs to run near vertical (+/- 1/2 ). Adjust drive line cord on roll tube if needed. Roller guide 5-14 Pulley bracket Center rope with center of roller guide C. Select solid bolting locations (such as rivet lines or ribs) for all bolts to be vertical with drive line. Remove knock outs and make marks. For center bolt, select and mark best location along laser etching of spring box. Before drilling, ensure all marks are at solid locations on spring box and aligned with center of roller guide. Drill 5/16 holes at marks. CAUTION: Do not bolt to box at this time, wait until step 14C. 28

29 14B. MOUNTING SPRING BOX HORIZONTALLY A. At front of trailer with roll tube hanging down, position spring box 5 to 14 down from roll tube clear of any interference and make mark at each end of spring box. B. Orient spring box so pulley bracket is at same end as drive line cord. Align notches on spring box with center of roller guide. Drive line cord needs to run near vertical (+/- 1/2 ). Adjust drive line cord on roll tube if needed. Roller guide 5-14 Adjust spring box to align notch with center of roller guide Pulley bracket C. near drive line (4 and 12 from front of trailer) and last bolt near opposite end of spring box. Remove knock outs and make marks. For three center bolts, select and mark best locations along laser etching of spring box. Before drilling, ensure all marks are at solid locations and notches on spring box align with center of roller guide. Drill 5/16 holes at marks. CAUTION: Do not bolt to box at this time, wait until step 14C. Roll tube 5-14 Drive line Short spring box knock outs Place center bolt at laser etching Place last bolt at knock out Roll tube 5-14 Drive line Long spring box 5-14 knock outs Place three center bolts at laser etching Place last bolt at knock out 29

30 14C. MOUNTING SPRING BOX TO TRAILER D. After bolting locations are determined, on back side of spring box, apply self adhesive foam strips, one on top and bottom of each bolting location. Self adhesive foam strips Self adhesive foam strips E. Use a 3/8 x 1 self threading bolt to cut threads for button head bolts at all locations. F. Realign spring box with holes and secure with a button head bolt and 3/8 7/32 Allen wrench. 30

31 15. INSTALL TENSION SPRING A. Place wear tube in spring box with opening facing down and away from box as shown. Spring box Wear tube with opening facing down and away from box B. Place spring inside of wear tube (not shown below for illustration purposes) on ledge of spring box with spring loop on opposite end of pulley bracket. Hold and insert 3/8 x 2-3/4 bolt and spacer bushing, secure with lock nut, tighten until snug. Spring Box Spring 3/8 x 2-3/4 bolt 3/8 Bushing Lock nut 31

32 16. ATTACHING DRIVE LINE CORD TO SPRING/SETTING TENSION Pulley bracket slot Route cord behind clevis pin Route cord behind pulley bracket A. Vertical: Route drive line behind pulley bracket and clevis pin at end of spring box, over and around pulley on the end of tension spring and back toward pulley bracket slot at end of spring box. Drive line cord Pulley bracket slot Start here Pulley in spring box B. Horizontal: Route drive line around pulley and in front of clevis pin at end of spring box, over and around pulley on end of tension spring and back toward pulley bracket slot at end of spring box. C. Pull cord snug tight and tie a knot on cord in line with V notch on spring box. V notch in spring box Knot tied in snug tight cord D. Pull cord through pulley bracket, stretching spring and place knot in pulley bracket slot. Place knot in pulley bracket slot Pulley lined up with rectangular notch E. Check spring tension after the tarp. Spring is properly tensioned when pulley settles back and lines up approximately with rectangular notch on spring box. With spring tensioned, wrap tape around cord 2 from knot and cut excess cord at that location. 32 NOTE: Always make sure drive lines are tensioned equally at front and rear of tarp.

33 17A. ATTACHING SPRING BOX SINGLE DOOR 5/16 x 3 pin and cotter key A. Align holes in door with holes at one end of spring box and insert 5/16 x 3 pin and cotter key. Swing door closed then repeat pin and cotter key installation at other end of spring box. CAUTION: Keep door closed with pin in place while operating. Repeat steps 13 through 17A to wrap drive line cord on roll tube and install spring box at rear of trailer. 17B. ATTACHING SPRING BOX DOUBLE DOORS 5/16 x 3 pin and cotter key A. Align holes in untabbed door with holes at end of spring box and insert 5/16 x 3 pin and cotter key. Repeat pin and cotter key installation for tabbed door at front of spring box. Untabbed door Keeper pin Tabbed door B. Swing doors closed with tab door overlapping opposite door. Push Insert keeper pin through doors and base of box. CAUTION: Keep door closed with pin in place while operating. Repeat steps 13 through 17B to wrap drive line cord on roll tube and install spring box at rear of trailer. 33

34 18. INSTALLING DRIVE CARTRIDGE Front end of roll tube Protective sleeve Drive cartridge Vinyl cap At front of roll tube, slide protective sleeve over roll tube. Slide drive cartridge in end of roll tube. Slide vinyl cap over cartridge shaft and onto roll tube. Cartridge shaft should protrude out of roll tube as shown with vinyl cap in place. NOTE: Drive cartridge is left loose to allow for adjustment when squaring motor arms with roll tube in later step. 34

35 19. INSTALLING PIVOT MOUNT (On Vertical and Slant Wall) A. Secure both halves of the pivot mount using 3/8 x 1-1/2 stainless steel carriage bolt, lock washer and nut through the bottom hole as shown below. Pivot mount parts Stainless steel nut Stainless steel lock washer 3/8 x 1-1/2 stainless steel carriage bolt B. Slide stainless steel square nuts into channels on support plate. Secure washers and lock washers threaded into the square nuts in the channel. hardware. Stainless steel 3/8 square nut Pivot mount Pivot mount support plate Stainless steel 3/8 square nut 3/8 x 1 stainless steel bolt Stainless steel lock washer Stainless steel 35

36 20. PIVOT MOUNT/SUPPORT PLATE LOCATION Align center point of pivot mount support plate with centerline of box. Measure down from top of end cap and mark holes for drilling. View shows vertical wall box. Do the same on slant wall box (See bottom of page). If unable to place at recommended location, pivot mount can be Make sure telescopic arm has a clear pathway to operate. NOTE: Pivot mount support plate should be attached to support braces whenever possible. C L Pivot mount and support plate centered on box Measure down to center of pivot mount support plate 47 Min 55 Max C L Centerline of box Maintain 5 of clearance from obstructions below Slant wall trailer Measure down on slant wall as shown 47 Min 55 Max Mark hole pattern locations C L C L Maintain 5 of clearance from obstructions below Pivot mount support plate 36 TIP: Hold pivot mount support plate in position with centerline and mark hole locations in line with support braces using grooves on support plate as guide. Note, on slant wall installs, hole pattern will tilt downward from measured centerline. DO NOT DRILL HOLES YET!

37 20. PIVOT MOUNT/SUPPORT PLATE LOCATION (continued) NOTE: Before drilling any holes, make sure telescopic arm has a clear pathway to operate. A. Drill 5/16 holes where marked. Attach pivot mount support plate to box wall by turning 3/8 x 1 self threading bolts to cut threads then turn back out. Secure using 3/8 x 1-3/4 stainless steel bolts, whenever possible use nuts on back side. NOTE: Bolt locations may vary from what is shown below based on locations of support braces on trailer. Stainless washer Stainless steel lock washer Stainless steel nut Pivot mount support plate 3/8 x 1-3/4 stainless steel bolts C L Pivot mount needs to be centered on box Pivot mount support plate bolted on box Centerline of box IMPORTANT: Before proceeding make sure pivot mount is centered on box. Tighten all hardware at this time. 37

38 21. BOLTING PIVOT ARM TO PIVOT MOUNT NOTE: The motor, gear box and arms are pre-assembled. The lower pivot arm slides inside the larger motor arm with wire routed inside both arms. Assemble pivot plate, with slotted holes up, to pivot mount. Use 3/8 x 1 and 3/8 x 1-1/2 stainless steel carriage bolts, lock washers and nuts. Leave bolts loose for now. 3/8 x 1 stainless steel carriage bolts Pivot mount support plate bolted to box 3/8 stainless steel nuts w/ stainless steel lock washers Pivot mount Pivot plate with slotted holes up 3/8 x 1-1/2 stainless steel carriage bolts 38

39 22. VERTICAL ALIGNMENT OF MOTOR ARM Vertical wall Slant wall When arm is perpendicular to roll tube tighten carriage bolts Lift arm to vertically align motor and arm as shown. Make sure pathway of motor and arm is free of obstructions (ladders, etc.), tighten carriage bolts now. 39

40 23. CONNECTING MOTOR/GEAR BOX TO DRIVE Protective sleeve Cotter pin #12 Phillips head screw Motor / gear box Apply grease to motor shaft. Raise arm with motor up and insert shaft into drive cartridge. Secure shaft to tube with cotter pin. A clevis pin is installed in step 24). When possible maintain 1 clearance between protective sleeve and drive line cord. Secure with #12 Phillips head screw. Ensure drive line cord has a clear path of travel throughout entire cycle of motor. 40

41 24. SQUARING MOTOR ARMS WITH ROLL TUBE 90 Protective sleeve A. Square the motor pivot arm with roll tube by adjusting the drive cartridge in or out as needed. You may need to remove the pivot bolt and check the position of the arm. Then adjust the cartridge in or out as needed. NOTE: Trim cutting the end of the roll tube shorter may be necessary in some cases. 6-1/2 B. After pivot arm is squared with tube, measure along side of tube, 180 opposite of rope channel, and mark 6-1/2 in from beginning of drive cartridge. 180 C. Drill 5/16 hole through roll inside of tube. Insert 5/16 x 9/32 drive rivet. Make sure rivet is fully seated. Set with hammer. Set 5/16 drive rivet 41

42 25. REAR TUBE CAP & TARP TUBE FASTENERS A. On back of trailer, install black cap over end of roll tube. Wide tarp stop at front and rear of tarp 1 Stationary tube Tighten set screw with Allen wrench B. Check to make sure stationary tube is centered on box. At front and rear wide tarp stops, tighten set screws with Allen wrench. IMPORTANT: These set screws prevent tube and tarp system from sliding back when raising box or from road vibration. 42

43 26. INSTALLING CONNECTOR SOCKET TIP: Dielectric silicone is provided for electric wire connections. Use as needed. Dual pole mount bracket Connector socket Lock washer Nut Flat washer A. Bolt connector socket to dual pole mount bracket using 5/16 x 1 bolts, 5/16 x 1 bolt Rear of connector socket Socket Terminal Heat shrink B. Before cutting wire, form a loop on arm that provides enough wire length for movement to connector socket on dual pole mounting bracket. Mark where to cut wires. Cut wires, strip ring terminals and heat shrink tube. Attach wires to connector socket terminals. Stripped wire end Ring Terminal Square nut (x2) Protective fabric C. Slide (2) square nuts into channel on pivot mount. Place protective fabric between dual pole mounting bracket and pivot mount and secure dual pole mounting bracket with 3/8 x 3/4 bolts and lock washers. Lock washer 3/8 x 3/4 bolt Dual pole mounting bracket 43

44 27. ELECTRIC WIRING INSTRUCTIONS NOTE: If installing an optional tarp control box, skip steps Use instructions supplied with the tarp control box. A. WIRE ROUTING - HEAVY GAUGE Select best routing of wire from battery to solenoid usually along frame with other wire harness along cab and up to pole connectors. Heavy gauge double strand wire (from solenoid to tarp motor) HD dual pole connector 14 ga. wire from switch to solenoid For wireless units only 5 length of wire (included in kit) from remote control box to dual pole plug Solenoid Stop Warning Decal Remote control box (wireless kits only) Caution/Operating decal & warning decal Rocker switch inside cab Circuit breaker 40 Amp Heavy gauge double strand wire (from battery to solenoid) IMPORTANT! Peel warning stickers from sheet and attach to visible area near unloading controls inside cab and on box or trailer. Place only the lower portion of this decal in a location visible to the operator or all warranties are void! DO NOT WALK OR STAND ON END CAPS. STAY CLEAR OF MOVING PARTS DO NOT OPERATE THIS VEHICLE, AT HIGHWAY SPEEDS, WHILE THE TARP SYSTEM IS IN THE OPEN POSITION DO NOT LOAD OR UNLOAD WITH TARP SYSTEM IN CLOSED POSITION. OPERATING INSTRUCTIONS EZ-LOC ELECTRIC TARP OPERATING PROCEDURE HOLD SWITCH UNTIL MOTOR CRANKS THE TARP UP UNDER THE LATCH PLATE TO OPEN TARP HOLD SWITCH TO THE OPEN POSITION. RELEASE SWITCH WHEN TARP IS FULLY OPENED. TO CLOSE TARP HOLD SWITCH TO THE CLOSE POSITION. RELEASE WHEN TARP IS FULLY CLOSED UP UNDER LATCH PLATE. SN AGRI-COVER, INC. P.O. BOX 508 JAMESTOWN, ND PN 50390_A Caution/Operating Decal 44

45 27. ELECTRIC WIRING INSTRUCTIONS (continued) B. SWITCH LOCATION AND INSTALLATION Select convenient location in cab to mount switch bracket with two #14 x 1 self drilling Phillips screws through slots in back of bracket. Route 14 ga. wire from switch to location of solenoid near battery. Rubber grommet is supplied for area where wire enters cab, 11/16 hole is needed for grommet. At switch, strip 14 ga. wire ends about 3/8 back and attach push-on connectors and crimp. Pull wires through mount bracket and attach to switch. Snap switch into mount bracket. Black to open Green to center White to close Front of bracket #14 x 1 Phillips head screw C. CAUTION/OPERATING AND STOP WARNING STICKERS Locate a suitable location at front driver side of box. Clean surface and apply caution sticker (See page 44). Locate visible area near unloading controls inside cab and on box. Clean surface and apply STOP warning stickers. D. SOLENOID Mount solenoid in protected area near battery using #2 x 1 self drilling Phillips screws. Then follow wiring connections on page 46. For reference see schematic on page

46 ELECTRIC MOTOR DRIVE WIRING CONNECTION INSTRUCTIONS (continued) E. LIGHT GAUGE WIRES Prepare end of black and white light gauge wires from switch with push on connectors for solenoid terminals. Connect white wire to left terminal. Connect black wire to right terminal. Prepare end of light gauge green wire from switch with 1/4 ring terminal. F. HEAVY GAUGE WIRES Split heavy gauge wire at solenoid about 4 back. Prep ends of black and red heavy gauge wires leading from motor and battery with heavy gauge 1/4 ring terminals, heat shrink tubes and rubber boots for (4) solenoid studs if needed. Attach wires to solenoid studs as shown on wiring schematic on page 47. Note the light gauge jump wire leads through same rubber boot with black (-) wire from battery. The green wire from the switch leads through the same rubber boot with red (+) wire from battery. Tighten nuts on terminal - always hold base nut while tightening top nut. Do not over tighten. Connect the white light gauge wire to left terminal and black wire to right terminal (See wiring schematic on page 49). G. CIRCUIT BREAKER Install circuit breaker in line on red (+) wire close to battery using #10 ring terminals and heat shrink. (prep wires as shown) 1/2 ring terminal for (+) battery post 3/8 ring terminal for (-) battery post #10 ring terminals for circuit breaker 1/4 ring terminals for solenoid and motor terminals 5/8 Typical for all heavy gauge wire eyelets Typical heat shrink tube for all heavy gauge wire connections Rubber terminal boots for solenoid connections only FIGURE 27A 46

47 27. ELECTRIC WIRING INSTRUCTIONS (continued) H. BATTERY Prep end of heavy gauge black wire for battery (-) post with heat shrink tube and 3/8 ring terminal. Prep end of heavy gauge red wire for battery (+) post with heat shrink tube and 1/2 ring terminal. Connect wires to battery now. Motor terminals are pre-wired 1/4 terminal at motor _ + 1/2 Terminal Heat shrink tube (typical) Red Red 1/4 Terminal 3/8 Terminal Circuit Breaker Always hold base nut while tightening top nut NOTE: DO NOT OVER TIGHTEN Green Black Black Jump wire Flat washer #10 x 1 self drilling Phillips head screw White #14 x 1 self drilling Phillips head screw FIGURE 27B INSTALLATION TIP: See wire schematic page

48 28. MOTOR DRIVE CONNECTION Using motor switch, align motor shaft hole with tarp shaft hole. Insert clevis pin and cotter pin. Bend tabs to secure. Grease the zerk at this location. Bend tabs on cotter pin Clevis pin Split cotter pin 48

49 ROCKER SWITCH WIRE SCHEMATIC DIAGRAM Plug terminals factory wired RED HEAVY GAUGE BLACK HEAVY GAUGE BLACK HEAVY GAUGE RED HEAVY GAUGE Solenoid Motor terminals factory wired RED HEAVY GAUGE Green 14 ga. White 14 ga. Jump Wire Black 14 ga. MOTOR Close Open ROCKER SWITCH (IN CAB) BLACK HEAVY GAUGE 40 AMP Breaker BATTERY 49

50 OPTIONAL MOUNTING BRACKET FOR SPRING BOX INSTALLATION (Not included with tarp kits) If needed, call and order kit #70299 or purchase online from our website. NOTE TO INSTALLER: This bracket is intended as an alternative mounting point if needed when installing spring boxes on trailer with exterior structural ribs. 1. Position bracket on solid mounting surface of box wall (between ribs) so it 2. Mark bolting locations. Drill 5/16 holes. Fasten bracket to box wall with 3/8 x 1 self threading bolt (x2). washer and lock washer (included in kit) on back side of wall to secure bracket. 3. Mount spring box to bracket using button head bolts and lock nuts as installation section of the owner s manual. Lock nuts (x2) Trailer rib Spring box Special bracket 3/8 x 1 self threading bolt (x2) Button head bolts 50

51 ORDERING A REPLACEMENT TARP your tarp s serial number and call Serial number is located at rear of tarp on stationary tube side. 51

52 MANUFACTURER S LIMITED WARRANTY Agri-Cover, Inc. extends the following limited warranty on its AUTOLOCK Electric Tarp to the original retail purchaser: Agri-Cover, Inc. warrants its AUTOLOCK Electric Tarp to be free from defects in material and workmanship under normal use for one (1) year from date of manufacture unless accompanied by proof of purchase. The one (1) year warranty start date can be found on the unit (motor and gearbox). Check both and refer to the oldest date shown. ANY IMPLIED WARRANTY APPLICABLE TO THE AUTOLOCK ELECTRIC TARP IS LIMITED IN DURATION TO ONE YEAR FROM THE DATE OF MANUFACTURE UNLESS ACCOMPANIED BY PROOF OF PURCHASE. Agri- Cover Inc. s sole obligation under this warranty or any implied warranty is limited to the repair or replacement at its option, of defective parts only. No labor or service allowance is given or implied. IN NO EVENT SHALL AGRI-COVER, INC. BE LIABLE FOR INCIDENTAL, CONSEQUENTIAL, OR SPECIAL DAMAGES. Some states do not allow limitations on how long an implied warranty lasts or exclusions of incidental or consequential damages, so the above limitations and exclusions may not apply to you. For warranty call our Customer Service Department at to determine if only a replacement part is needed or if the cover needs to be returned for inspection and repair. Goods to be returned must have a preauthorized RA # (Returned Authorization Number) obtained by calling the number above. Mark the number on the package and ship it freight prepaid to address below. Agri-Cover will pay freight to return goods to sender. This warranty does not cover any failure due to abuse, misuse, alteration, neglect, improper assembly or installation, or improper maintenance. vary from state to state. For replacement parts, shop at tarpreplacementparts.com or call Customer Service at Agri-Cover, Inc. Customer Service Dept PO Box Hwy 281 SE Jamestown, ND Phone: Hours: 8:00 am - 5:00 pm CST Monday through Friday, except Holidays AUTOLOCK is a registered United States trademark of AGRI-COVER, INC AGRI-COVER, INC. ALL RIGHTS RESERVED. 52 Product subject to change without notice. Patents: agricover.com/patents _7