Steel Protector, 7 Aluminum Windguard, 9 Open & Steel Protector Plus w/electric Drive Conversion Kit Installation Instructions

Transcription

1 WLH 0/0/ 0-0, 0-09, 0-0, 0-0 (0-0 Configuration) 0-0

2 TABLE OF CONTENTS ***Assembly*** ***Wiring, Parts & Tools Required*** Securing Roller and Removing Tarp... Electric Motor Wiring and Plug Assembly... Removing Roller Tube... Electric Motor and Breaker Wiring... Roller Tube End Cap Installation... EDU Conversion Kit Components and Tools Required Roller Tube and Electric Motor Installation... Roller Tube and Electric Motor Installation... Tarp Reinstallation... i

3 Securing Roller and Removing Tarp Step : Extend tarp until it is completely unrolled from the roller tube (Fig & ) and over the tail gate. Once tarp is fully extended, tie off at the end of the tail gate, so tarp will not roll back. Side View (Fig. ). Fig. Fig. Fig. Housing Side Panel Hem Tube & Tarp Note: The Steel Protector is to remain on box during entire conversion. Fig. Insert / x bolt into groove. Step : Roll the roller tube hem tube groove to allow for insertion of the included / bolt. When the two are aligned, hold the tube in place and insert the bolt into the hole and roller tube. This will assure that the roller tube will not rotate as the tarp is removed (Fig. ). Fig. Insert / x olt into groove. Make sure bolt is secure in Hem Tube groove. Roller Tube & Hem Tube Groove Step : Once roller tube is secure, remove tarp from groove through slot on the right side of the Steel Protector (Fig. ) and set aside.

4 Removing Roller Tube Fig. a Hold tube tight. Fig. b A. Remove bolt. B. Release tube. Tube spins fast. Step : With bolt in roller groove, hold roller tight with hand then use other hand to remove bolt (Fig a). Once the bolt is removed, let go of the roller to release the spring tension (Fig. b-a & B). When released, the roller tube will spin rapidly until all tension is released. Note: Mounting bolts not shown. Fig. Step : Remove the end plate and Fig. roller tube from the housing (Fig. ). Note: The mounting bracket will need to be reused with the new end plate. Step : Remove the screw that retains the End Cap (Shaft End). Place a piece of cardboard on the ground and hold the roller assembly vertically, with the end plate towards the ground. Shake the roller assembly up and down above the cardboard to pop the end cap and spring assembly free from the roller tube (Fig. ). Note: The cardboard is to protect the end of the spring shaft when it breaks free. System Mount Bracket welded to truck.

5 Roller Tube End Cap Installation Wrap tape around tube. /" Masking Tape Cut here. Hack Saw Step : Position the roller tube on a flat surface. Cut roller tube / from end using a hack saw (Fig. 9). Fig. 9 Fig. 0 Fig. a Note: Use masking tape wrapped around tube as a cutting guide. File end of tube till free of rough edge. Fig. b Step : After cutting off the / section and removing the masking tape (Fig. 0), file the edges to smooth out end of tube and provide a better fit for the end cap. Step 9: Insert end cap into roller tube. Use a rubber mallet to tap the edges of the end cap lightly to ensure that it has been seated properly (Fig. a & b). Fig. Note: Be careful not to make a dimple on the seam on the back of the roller tube. A C B D B D Step 0: To secure the end cap in the roller tube, make four () indentations or dimples to hold the end cap in place. Use a mallet and flathead screwdriver to make the dimples (Fig. - A, B, C & D). WARNING: Do not make indentation on welded seam. Dimple detail (Fig. ). Dimple ( of ) End Cap Fig. Roller Tube

6 Roller Tube and Electric Motor Installation Step : Insert Roller tube into Steel Protector Housing (Fig. -A) and secure to Electric End Plate (Fig. -B) using existing fasteners. Fig. (A) Fig. Step : Insert three () HHCS bolts (Fig. ) to allow for the Electric Motor to be mounted on the side of the Steel Protector. (B) () () () () () () System Mount Bracket welded to truck. Step : With the HHCS bolts in place, attach and secure the Electric Motor (Fig. ) to the Electric End Plate using a / wrench. Fig. Fig. Step : With the Electric Motor in place, secure with three () HHCS Bolts (Fig. ). Note: Make sure the motor shaft is inserted in the roller tube end cap.

7 Roller Tube and Electric Motor Installation Fig. a Fig. b Step : Wire motor with Switch Kit per instructions on page &. Step : Place Electric Motor Cover on the mounted motor (Fig. a) and then secure with two () mounting screws (Fig. b). Electric Motor & Cover Step : With the Electric Motor drive shaft inserted into the roller tube end cap, install the HHCS bolt, flat washers and nyloc nut (Fig. 9a & b) and tighten. Note: Make sure the roller tube is firmly secured to the Electric Motor shaft. Fig. 9a Fig.9b Electric Motor & Cover Steel Protector Housing Bottom view of roller tube without housing.

8 Tarp Reinstallation Step : Slide the edge of the tarp into the housing and roller tube groove (Fig. 0). Fig. Step 9: Slide tarp in roller tube groove until it is flush with the other side (Fig. ). Roller Tube. Insert end of tarp into roller tube groove. Tarp Fig. 0 Slide tarp. Fig. Step 0: Once the tarp is installed and square on the box, use the electric motor to retract tarp (Fig. ). Note: See electric motor wiring instructions on page &. Special note: If installing an Arm Kit, use Spring Kit instructions from here on.

9 Electric Motor Wiring and Plug Assembly Fig. * Trailer Connector Detail Step B - Wiring: Assemble the Quick Disconnect as shown (Fig. ). Battery Step A - Wiring: First, remove motor housing, then run the ga. wire to both locations (motor & battery box) and attach to truck body (Fig. ). Note: The wire must go beyond the pivot point. Caution: Make sure wire does not get pinched at the pivot. /" Breaker Fig. Trailer Connector* Fig. Terminal # Dump Pivot Switch Fig. Wire Fig. Step D - Attaching The Connectors (Motor):. Split the molded ga. wire approximately " and strip the ends about /" down.. Attach connectors (part # -00) and crimp (Fig. ).. Attach black wire to Terminal # on motor (Fig. ).. Attach red striped wire to Terminal # on motor (Fig. ). Note: Wire Cutters required. Pin Connector Spring Tab Step C: Crimp or solder pin to wire (Fig. ). Note: Make sure the pin snaps over the end of the spring tab. ga. /" Lug Connector (part # -00) Terminal #

10 Electric Motor and Breaker Wiring ga. /" Lug Connector (part # -00) /" To motor Step E:. Mount the Control Box at tailgate.. Spilt the ga. wire at the Control Box about " back and slip on rubber boots Red Boot (part # -09) on red striped wire and Black Boot (part # -0) on black wire (Fig. & 9).. Strip wire about /"and attach connectors (part # -00) (Fig. ).. Attach Red Striped wire to Motor (+) and Black wire to Motor (-) on Control Box (Fig. 9). Note: Do not over tighten nuts on connections! Fig. Fig. 0 ga. #0 terminal ends (Part # -00) Step F:. Mount breaker in the battery box away from moisture.. Cut a section in the red ga. wire that will run to the postive terminal on the battery.. Strip wire the ends about /" and attach ga. #0 terminal ends (part # -00) (Fig. 0).. Attach to breaker. Battery Fig. Battery Aux ga. wire Light 0 Amp "Non Cycle" Breaker Note: Mount as close as possible to power supply. To reset, disconnect power. ga. wire Fig. 9 Wiring Diagram (Fig. ) - To Ground Motor Forward & Reverse Switch ga. wire ga. wire Motor Amp Push To Reset Circuit Breaker Motor check out procedure:. Remove leads from motor & attach volt meter to the leads.. With the switch in the on position, the volt meter should read volts minimum. If voltage is low recheck with engine running. Recheck wiring and connections (minimum gauge wire must be used).. Return switch to the neutral position & reattach leads to motor.. Attach volt meter to leads at the motor.. With the switch in the on position and the leads attached, the volt meter should read. volts minimum. If voltage is low recheck with engine running. Recheck wiring and connections (minimum gauge wire must be used).. Return switch to the neutral position and attach amp meter to leads at the motor.. With the switch in the on position, amp meter should read approximately 0 0 amps. Constant amperage reading of over 0 amps indicated binding in the system and/or low voltage.

11 Steel Protector Housing Converstion Kit: 0-0 ITEM PART # DESCRIPTION QTY -090 V DC Electric Motor 0-0 / - Nyloc Nut 0-0 / Flat Washer USS 0-0 Electric End Plate N System 0-0 / Lock Washer 0-0 / - x lg. HHCS Bolt 0- System Mount Bracket (Left) 0-0 / - x / lg. Carriage Bolt / - 0 x / lg. Carriage Bolt / - x -/ lg. HHCS Bolt 0-0 / - 0 x Nyloc Nut (Thin) 9 0 Aluminum Windguard Conversion Kit: 0-09 ITEM PART # DESCRIPTION QTY -090 V DC Electric Motor. HP V DC Electric Motor. HP X Mounting Bar (Steel or Aluminum) Folded Ele. Alum. End Plate (Drvr.) 0-0 / - Nyloc Nut 0-0 / Flat Washer USS 0-0 / Lock Washer 0-0 / - x lg. HHCS Bolt 0-0 / - x -/ lg. HHCS Bolt Aluminum Driver End Cap / - x / lg. HHCS Bolt 0-0 / - x / lg. Carriage Bolt 0 9 9

12 9 Open Conversion Kit: 0-0 ITEM PART # DESCRIPTION QTY -090 V DC Electric Motor. HP V DC Electric Motor. HP / - Nyloc Nut 0-0 / Flat Washer USS Open End Plate, Electric (Drvr.) 0-0 / Lock Washer 0-0 / - x / lg. HHCS Bolt 0- Open System Mount Bracket (Steel) 0-0 / - x / lg. Carriage Bolt / - x -/ lg. HHCS Bolt Roller Drive Aluminum End Cap 0 9 Steel Protector Plus Conversion Kit: 0-0 ITEM PART # DESCRIPTION QTY -090 V DC Electric Motor. HP V DC Electric Motor. HP / - Nyloc Nut 0-0 / Flat Washer USS 0-X System Mount Bracket (Left) (Steel or Aluminum) 0-0 / - x / lg. Carriage Bolt 0-0 Electric End Plate N System 0-0 / Lock Washer 0-0 / - x / lg. HHCS Bolt / - x -/ lg. HHCS Bolt Roller Drive Aluminum End Cap 0-0 / - 0 Nyloc Nut 0-0 / - 0 x / lg. Carriage Bolt 9 0 0

13 Tools Required ITEM DESCRIPTION QTY Hack Saw Adjustable Wrench Rubber Mallet Metal File Flathead Screwdriver Masking Tape Wire Cutters /" Wrench