EZ-LOC HAND AND ELECTRIC INSTALLATION INSTRUCTIONS AND OWNER S MANUAL

Transcription

1 EZ-LOC HAND AND ELECTRIC INSTALLATION INSTRUCTIONS AND OWNER S MANUAL TYPICAL OF FARM TRUCK, GRAIN CART, AND SEMI-TRAILER BOXES INSTALLER: These instructions must be given to the consumer. CONSUMER: Retain these instructions for future use. READ ALL INSTRUCTIONS CAREFULLY BEFORE INSTALLING OR USING THIS COVER. BY:

2 n PREPARATION/TOOLS and 3 n INSTALLATION INSTRUCTIONS n OPERATING INSTRUCTIONS HAND CRANK and 17 ELECTRIC CONTENTS n SAFETY INFORMATION , 16, 19 and 23 n INSPECTION AND MAINTENANCE n PARTS DIAGRAMS and 24 n PART DESCRIPTIONS , and 25 n WARRANTY Back Cover This owner s manual applies to the EZ-LOC Hand Operated Tarp and the EZ-LOC Electric Operated Tarp systems. For your convenience the following symbols appear throughout these instructions to aid in installing, operating and maintenance of your tarp system. This symbol alone means the step will apply only to the hand crank operated tarp. This symbol alone means the step will apply only to the electric motor operated tarp. Both symbols together means the step applies to both hand and electric operated tarp systems. This symbol is intended to alert you to important installation, operating or maintenance instructions in this owner s manual. IMPORTANT Promptly confirm your warranty by registering on-line at FOR YOUR RECORDS: DATE PURCHASED WHERE PURCHASED SERIAL NUMBER

3 NOTICE: NOTICE TO INSTALLER: It is recommended you take the time to read these instructions before installing this cover even if already familiar with the product. Often improvements are made without prior notice. Always handle cover and components with care to avoid damage. If you find a part missing or defective, or if you are having trouble installing this product, please have serial number ready (found on decal included with kit) and call the customer service number on the back page. When done, these instructions and warranty information must be given to the consumer. NOTICE TO CONSUMER: Before using this product, read the operating instructions, maintenance and safety sections of this owners manual and save for future reference. PREPARATION TOOLS & EQUIPMENT Most installations will require use of all these items 1. Protective eyewear 2. Marking pencil 3. Step ladders or scaffolding 4. Lock plier 5. Drill with 5/16 and 3/8 drill bits 6. Tape measure 7. Impact wrench with 9/16 socket 8. Two 1/2 wrenches, a 9/16 and 3/4 wrench 9. Hammer 1. Protective eyewear 2. Marking pencil 3. Step ladders or scaffolding 4. Lock plier 5. Drill with 3/16, 7/32, 5/16, 3/8 and 11/16 drill bits and #3 Phillips driver bit 6. Tape measure 7. Impact wrench with 9/16 and 3/8 sockets 8. Wrenches: (2) 1/2, (2) 9/16 and a 3/8 9. Hammer 10. Wire cutter, crimper and stripper 11. Heat gun 12. #25 Torx driver 13. Torque wrench (inch lbs.) 14. 1/8 Allen Wrench 15. #1 Phillips Head Screw Driver 16. 1/2 Wrench 17. 1/4 Drill Bit -2-

4 PREPARATION IMPORTANT NOTES: The illustrations used in this manual show a semi-trailer box, however steps and procedures also apply to farm trucks and grain carts. 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. Inspect box for sharp edges or points that make contact with tarp and or cables, remove or grind smooth. Box must be square and straight, center must not be pulled together or spread apart. Make adjustments prior to installation. It may be necessary to remove or reposition ladders or other devices that may interfere with tarp. If any modifications to box are needed, consult box manufacturer before doing so. 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 a 3/8 x 1 self threading screw. A 5/16 hole must be drilled to obtain correct tap drill hole size. Attach these screws 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. EZ-LOC STAINLESS STEEL KIT ONLY 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 and 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 screws: Use these to cut threads into 5/16 holes in areas where you cannot get at to turn nuts on. Drill 5/16 hole. Turn 3/8 self threading screw in hole to cut threads, then turn it back out. Turn 3/8 x 1 SS bolt in for attachment.

5 INSTALLATION INSTRUCTIONS STEP 1: MOUNTING THE END CAPS A. WEATHER SEAL Clean underside of cap for adhering weather seal. Repeat on each end of front and rear end cap. Factory Installed Edge Guard End Cap Align Weather Seal Edge Guard IMPORTANT: Sharp edges cause tarp damage not covered by warranty. Make sure end cap at ends 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. Push end cap down tight against top of box. Tarp Approx. 1/2 Weather Seal 1) Align weather seal as shown. Test fit end cap and adjust seal location as needed. 2) Adhere weather seal to cap. Repeat procedures at both ends of end cap NOTE: Before adhering weather seal, make sure end caps will fit box. Sometimes caps may need to be trim cut for special situations. See Illustration 12 and installation tip on Page 4. ILLUSTRATION 1 3) Push down on end cap to compress seal and hold. Then mark and drill holes to mount end cap. See important note above -3-

6 FRONT END CAP Do not stand or walk on end cap. style end cap on front of box. Center it. Hold firmly in place against box, drill 5/16 TIP: Sometimes it is necessary to modify end caps for proper fit by notching overhang, removing protruding objects from box, or by trim cutting them shorter if too wide for box. Both front and rear end cap should measure at least 1/2 inch narrower than top of box. Maintain Equal Dim. On Both Sides Front End Cap Cap Must Be Shorter Than Box 1/2 Inch Min. 1-1/2 Inch Max. (Standard mounting - if using optional brackets see next page) 3/8 Self Threading Screw Drill 5/16 Hole Hole At Etched Mark On Cap 3/8 x 1 Self Threading Screws At Each Hole In Cap FRONT VIEW OF END CAP Push Center Of Tube Side Of Cap Up 1/4 - Then Mark And Drill Holes ILLUSTRATION FIGURE 1 1 ILLUSTRATION 2 A. FRONT END CAP Place side mount style end cap on front box. Center it. Hold firmly in place against box, drill 5/16 holes at each factory hole in face of cap. Fasten with 3/8 x 1 self threading screws. Illus. 1. B. Use factory etch mark on cap as guide, and drill 5/6 hole into top of box rail. Fasten with 3/8 self threading screw. Repeat at other end of cap. Illus. 2.

7 REAR END CAP Do not stand or walk on end cap. INSTALLATION TIP: Some kits require non-standard end caps. These kits will have 2 front style end caps. Skip rear end cap instructions and follow front end cap instructions for end cap at rear of box. 1/4 3/8 Self Threading Screw Drill 5/16 Hole At Etched Mark On Cap VIEW OF REAR END CAP Drill 5/16 Holes ILLUSTRATION FIGURE 3 3 ILLUSTRATION 4 A. Place rear cap (top style mount) on back of box and center it. Then adjust it to hang over box by 1/4. Mark deepest location of each slotted hole on top of box. Remove cap and drill 5/16 hole at each mark. Turn 3/8 self threading screw halfway in each hole. Slide end cap under screw heads. Position cap to overhang box 1/4 and tighten screws. -8- (Standard mounting - if using optional brackets see next page) -4- B. Push cap up 1/4 at center on ribbed side. Hold it at this angle and use factory etch mark as guide to drill 5/16 hole into top of box. Fasten with 3/8 self threading screw. Repeat at other end cap.

8 OPTIONAL END CAP ANGLE BRACKETS Pre-Formed Rib In End Cap (Do not place bow here) Pre-Formed Rib In End Cap (Do Not Place A Bow Here) Tilt Up 1/4 At Center Tilt Up 1/4 At Center 5/16 x 1 Bolts Flat Washers Lock Washers And Nuts End Cap Bracket 5/16 x 1 Bolts, Flat Washers, Lock Washers, And Nuts 3/8 x 1 Self Thread Screws Turned Into 5/16 Tap Hole End Cap Bracket (Inside Of Box) 2 Per End Cap 3/8 x 1 Self Thread Screws Turned Into 5/16 Tap Hole All Self Threading Screws Shown Partially Turned In To Allow End Cap Slots To Slide Under Screw Head, Then Finish Tightening. 1/4 Overhang At Rear Of Box SIDE VIEW OF FRONT END CAP SIDE VIEW OF REAR END CAP OPTIONAL END CAP ANGLE BRACKETS Center end cap brackets underneath sealing rib of end cap and butt up against inside of box. Mark center locations of slotted holes on box. Drill 5/16 hole and use a 3/8 x 1 screw. Tighten first screw, then drill second hole and tighten that screw. Next, drill 5/16 holes in center of slotted holes through end cap. Make sure cap is tilted up 1/4 and bolt in place with 5/16 x 1 bolt, flat washer, lock washer, and nut. NOTE: For stainless steel kits see page 3 for bolting procedures Washer Shim At Each Bolt Location Gap Area Filled With Sealing Tape Extra Layer Of Metal 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 cap at each bolt.

9 STEP 2: MOUNTING THE BOWS AND RIDGE STRAP 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 The first bow should be placed 30 from front of box. The last bow should be placed 30 from rear of box. Position remaining bows evenly spaced between first and last bow. See Illustration 6 on page 6 for bow placement. Attach bow pocket to inner sides of box, flush with top, using 3/8 x 1 self threading screws. See below. Box Rail Bow Extension Bow Pocket Drill 5/16 Holes In Box Rail Turn Self Threading Screws Into Holes - Insert Bow & Extension - Then Tighten Screws ILLUSTRATION 5-5-

10 INSTALLATION INSTRUCTIONS STEP 2: MOUNTING THE BOWS AND RIDGE STRAP (Continued) Standard One Ridge Strap In Center Last Bow At Rear Clamp lock 1 plier on bow extension to hold bow in place 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 screw. See tip below. B. BOWS Start with first bow at front of box. Insert bow extension into bow. Place each end of bow into bow pocket. Center it in an upright position. Adjust it to set 1 higher than end cap. Drill 5/16 hole through end of bow and in extension. Drill hole so screw head will not rub tarp. Turn 3/8 x 1 self threading screw in bow assembly. IMPOR- TANT: Purpose of bolt is to hold bow rigid at properly set height. See Illustration 6. Optional 2 Ridge Strap Off Center First Bow From Front 30 * Divide Remaining Space By Number Of Bows Left Plus One * 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 Warning: All Bows Must Be Used ILLUSTRATION 6 30

11 TIP: First set front and rear bows to correct height. Then install ridge strap on top of all bows and draw tight until no slack. Then adjust remaining bows to just touch bottom of ridge strap. Rear End Cap C. RIDGE STRAP Attach hook end of strap to hole in center of front end cap (or if two ridge straps, attach straps off to each side of center) and run strap over all bows to rear end cap. Twist Ridge Strap At Ratchet End Bow Then attach ratchet end of strap to rear end cap and draw strap tight. Do not over tighten. See Illustration 7. Front End Cap Trim Cut Excess Ridge Strap ILLUSTRATION 7-6-

12 STEP 3: STANDARD TARP STOPS INSTALLATION INSTRUCTIONS A. At front, start first tarp stop 12 from edge of box. With tarp centered on box, allow fixed tube to hang about 3 down from top rail. Position tarp stop over fixed tube, drill 5/16 holes and fasten with 3/8 self threading screws. Install remaining tarp stops spaced as shown in Illus. 8. ILLUSTRATION 8

13 OPTIONAL QUICK RELEASE TARP STOPS A. QUICK RELEASE TARP STOPS A. These Select brackets preferred secure tarp stationary rolling. For side normal of tarp tarp to box. roll, Select mount preferred brackets tarp on rolling. passenger For side normal of box tarp as roll, shown mount in instructions. brackets on For reverse PASSENGER tarp roll, SIDE mount OF BOX brackets as shown on driver throughout side these of box. instructions and Illustration 8 above. For reverse roll, mount brackets Place on DRIVERS first and last SIDE bracket OF BOX. preder- B. ably 12 in from each end of box. Divide B. Place first and last bracket preferably remaining space by number of brackets 12 left in from each end of box. Divide remaining space by number of brackets left plus plus one to get equal spacing. See Illus. 8. one to get equal spacing. See Illustration 8 C. above. Position brackets on outside wall of box ¼ down from top of rail. Mark locations to drill C. Position holes. bracket TWO holes on outside for interior of box brackets, so top FOUR of bracket holes is 1/4 for 1st down and from last top bracket. of box rail, Drill 5/16 mark two holes hole and locations, mount brackets and drill 5/16 with 3/8 holes. x 1 Then self mount threading bracket screws. with two See 3/8 Illus. x 1 9. self threading screws. See Illustration 9. D. Align lower hole in quick release tarp stops D. Align with lower bottom hole hole in quick in brackets. release tarp Insert stop with lower hole in bracket. Assemble with clevis pin and secure with bow tie pin. See clevis pin and bow tie pin. See Illustration 9. Illus. 9. Let brackets swing down in open Let bracket swing down in open position to position to receive tarp tube later. Save receive tarp tube later. Save upper clevis pin remaining and bow tie clevis pin for pin use and at bow that time. tie pins Repeat for later procedure step. C and D for all brackets. Slide Black Vinyl Tarp Protector Over Aluminum Tarp Stop (Drill 5/16 Holes For These Bolts) Use 2 3/8 x 1 Self Threading Bolts For All Interior Brackets 1/4 Down Slide Black Vinyl Tarp Protector Over Aluminum Tarp Stop Clevis Pins Clevis Pins 1/4 Down Bow Tie Pins Tarp Stop (Drill (Drill 5/16 5/16 Holes) Holes Drill Bow Base Tie Bracket For These 5/16 Bolts) and Use 4 3/8 Self Pins Use Threading Use 2-3/8 4 3/8 x Screws 1 x 1 Self Self For Threading Bolts Tarp Stop Threading First At First and And Screws Last Last Bracket Bracket Base Bracket VIEW AT TOP FRONT CORNER OF BOX (passenger side) VIEW AT TOP FRONT CORNER OF BOX (passenger side) ILLUSTRATION 9 pull it out from clevis pin. TIP: To remove bow tie pin, turn it 1/4 turn, then pull it out from clevis pin. 12 In From Each End of Box NOTE: For stainless steel kits see page 3 for bolting procedures TIP: To remove bow tie pin, turn it 1/4 turn, then -7-

14 STEP 4: LATCH PLATE A. Mount latch plate to side of box opposite from tarp stop brackets 0 to 3 down from top of box rail. Start flush with end of box and stop flush at other end of box. See Illustrations 10 and 11. 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. INSTALLATION INSTRUCTIONS TIP: Use C-clamps to hold latch plate in its proper position for drilling holes and bolting. Latch Plate Mounted Continuous Over Length Of Box - Flush At Each End. Latch plate is available in standard lengths of 8-0, 6-0, 4-0, and 2-0. On odd length boxes, 1 pc. of latch plate will have to be field cut. ILLUSTRATION 10

15 B. Using small groove line on latch plate as center point for drill bit, drill 5/16 holes spaced as shown in Illustration 11. Then fasten with 3/8 x 1 thread cutting screws. 3/8 x 1 Self Threading Screws Top Of Box Drill 5/16 Hole Centered On Groove (Typical) STEP 5: REAR TARP RETURN KIT NOTE: Kit is OPTIONAL for hand crank tarps. If ordered with tarp, install it at REAR of box as shown. Kit is STANDARD with Electric tarps. Install it AT FRONT OF BOX. Review Illus. 12 and 13 before proceeding. A. Starting at corner of box (rear if hand crank, front if electric) place first bunji guide at collar end of cord onto latch plate. Adjust it to extend 5/16 to 3/4 beyond face of end cap. Make sure cord s path will clear bolt heads on face of end cap. Hold bunji guide in correct position and mark hole location. Drill two 5/16 holes and fasten bunji guide with 3/8 self threading screws. See Illustration 12 and 13. Preferably 0 to 3 Start And Stop Latch Plate Flush At Edge Of Box Typical For First Screw In From Ends And Joints Typical Of All Remaining Screw Locations NOTE: For stainless steel kits see page 3 for bolting procedures ILLUSTRATION 11 ILLUSTRATION 12-8-

16 INSTALLATION INSTRUCTIONS STEP 5: REAR TARP RETURN KIT (Continued) B. At other end of cord, pull second bunji guide along top of latch plate until slack is out of cord. Then stretch it another 12 inches and mount bunji guide at that location by drilling two more 5/16 holes and fastening with 3/8 self threading screws. This applies pre-load tension to cord. Illustration shows installing at rear of box. For Electric kits, install at front-opposite of illustration. Mount bunji guide here NOTE: For stainless steel kits see page 3 for bolting procedures + 12 ILLUSTRATION 13 Pull Slack Out Of Cord Bunji Guide 3/8 x 1 Self Threading Screws (2x) 5/16 to 3/4 Bunji Guide 3/8 x 1 Self Threading Screws (2x) ILLUSTRATION 13 STEP 6: ASSEMBLING ROLL TUBE AND STATIONARY TUBE SPLICES (for kits that require splicing the tubes) A. SPLICING ROLL TUBES Kits with multiple roll tubes are shipped with splicer tubes. Check roll tubes for packing inside and remove if there. The splicer tube has predrilled holes to match with predrilled countersink holes on splice end of roll tubes. Arrange tubes on flat surface with splice ends together. Slide splicer tube inside 1st roll tube and align holes. Insert all 4 countersink drive rivets. Make sure each rivet is fully seated in hole. Then set with hammer.

17 Align rope channel on second tube with first tube and slide it over splicer tube. Align holes and insert all 4 rivets. Make sure each rivet is fully seated in hole. Then set with hammer. Each roll tube splice requires a total of 8 countersink drive rivets. 2nd Insert All 4 Countersink Drive Rivets To Ensure Hole Alignment Roll Tube Splice End TIP: Use socket to push rivet in hole and tap lightly with hammer to fully seat it Before Drilling, Align Tarp Rivet Holes With Each Other 3/16 Drive Rivet Drill 7/32 Hole Insert Swaged End Inside Standard End End Plug 3rd Make Sure Each Rivet Is Fully Seated And Set With Hammer Repeat Procedure For Other Half Of Splice Splicer Tube ILLUSTRATION 14 1st Align 4 Holes In Splice End Of Roll Tube With Holes In Splicer Tube Make Sure Rope Channel On Both Tubes Matches Press End Plug Into Tube And Tap In Place With Mallet ILLUSTRATION 15 B. One inch stationary tubes (if shipped in 2 pieces) are spliced by inserting swaged (undersized end on one tube into standard size end of other tube). Assemble joint, rotating tarp rivet holes at each far end until they are aligned with each other. Drill 7/32 hole through two layers of tube wall. Make sure rivet is fully seated and set drive pin with hammer (drive pin should be flush when done). -9-

18 INSTALLATION INSTRUCTIONS STEP 7: MARKING & DRILLING ROLL TUBE RIVET HOLES ATTENTION INSTALLERS: BEFORE attaching stationary tube and roll tube onto tarp, use these instructions to mark and drill 1 rivet hole in each end of roll tube. FOR HAND OPERATED KITS: 1)Align small (stationary) tube with factory drilled rivet holes next to large roll tube (without rivet holes) as shown. If roll tube or stationary tube is in two pieces, assemble splices tight first. 2)Use hole locations in small tube as guide and mark hole locations to drill 7/32 hole for riveting in large roll tube as shown. If roll tubes have rivet splicing, make sure longest section of tube from splice is orientated to front end opposite of crank handle according to diagrams below. 3)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 approx. 1 inch) to match rivet holes in tarp with rivet holes in tube. See Step 8.

19 STEP 7: MARKING & DRILLING ROLL TUBE RIVET HOLES ATTENTION INSTALLERS: BEFORE attaching stationary tube and roll tube onto tarp, use these instructions to mark and drill 1 rivet hole in each end of roll tube. FOR HAND OPERATED KITS: 1)Align small (stationary) tube with factory drilled rivet holes next to large roll tube (without rivet holes) as shown. If roll tube or stationary tube is in two pieces, assemble splices tight first. 2)Use hole locations in small tube as guide and mark hole locations to drill 7/32 hole for riveting in large roll tube as shown. If roll tubes have rivet splicing, make sure longest section of tube from splice is orientated to rear end and opposite of electric motor according to diagrams below. 3)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 approx. 1 inch) to match rivet holes in tarp with rivet holes in tube. See Step

20 INSTALLATION INSTRUCTIONS STEP 8: ATTACHING TUBES TO TARP INSTALLATION TIP: Tarp is designed to be stretched to reduce wrinkling when riveted to tubes. A. ROLL TUBE On a clean floor, lay tarp out flat with rope to top, (raw edge of hems, and pocket down) and exterior side facing up. Set front end of roll tube to rear of tarp. Refer to Illustra - tion 16 for front of roll tube indentification. Align roll tube channel with sewn in rope on tarp. Slide tube onto tarp rope, making certain that rope is fully engaged in rope channel on the tube. Small Tube Pocket Start Sliding Front Of Roll Tube At Rear End Of Tarp, Driver Side On Electric Motor System This Is Front Rivet Hole B. STATIONARY TUBE Insert small tube (1 ) into small pocket of tarp and slide in until even at both ends. Front End Of Tarp Driver Side On Hand Crank System This Is Front Rivet Hole On Tube ILLUSTRATION 16

21 STEP 8: ATTACHING TUBES TO TARP (Continued) C. Unfold factory assembled cord return, align open ends and connect tubes together. Insert assembly into front end of roll tube. Align groove on end plug with groove inside roll tube and tap in place. Fasten with Phillips head self drilling screw. See Illustration 17. (For electric tarp install this roll return in rear of roll tube.) D. At front end of tarp, align rivet hole in roll tube with rivet hole in tarp. Insert drive rivet making sure it is fully seated and set pin with hammer. Next on small tube, align rivet hole in tube with hole in tarp, insert drive rivet and after fully seated, set drive pin with hammer. E. At rear of tarp, by hand grip tarp and pull tight until slack and wrinkles come out. You may need assistance from another person to hold tube while stretching it to align holes and insert drive rivet. Then with rivet fully seated set pin with hammer. Repeat for opposite tube. TIP: Using a liner tool to find hole in tube and pull tarp in alignment so rivet can be PVC Tubes pushed completely in, makes this End Plug Phillips Head Screw procedure easier. ILLUSTRATION

22 A. ROLL TARP ASSEMBLY With tarp assembly completed and laying flat on floor straighten out any wrinkles. Roll tarp on tube by hand all the way over to small tube - all while roll is on floor. This is tarps natural open position. Locate tarp stop pins and lock rings and have them readily available for next sequence. Place tarp roll on top of stationary side of box (side with tarp stop brackets) and center it from front to back of box. CAUTION: DO NOT LET TARP ROLL OFF OF BOX DURING THE FOL- LOWING PROCESS. Place small tube with tarp into brackets, swing tarp stops up, align its holes with bracket holes and insert upper pin. Repeat for all tarp stops. This secures roll assembly to box. Insert all lock rings. See Illustration 18. INSTALLATION INSTRUCTIONS STEP 9: SETTING TARP ASSEMBLY UP ON BOX Unroll tarp by hand over bows and end caps to other side of box and let hang down. Check if tarp is still evenly centered from front to back of box - make adjustments if needed. ILLUSTRATION 18

23 STEP 10: CRANK HANDLE ASSEMBLY NOTE: For electric tarp installs, skip steps 10 through 12 Continue with step 13. A. U-JOINT/HANDLE EXTENSION Align sleeve end of U-joint with single hole end of handle extension. Make sure hole in u-joint is in line with hole on handle. Swing spline end 90 to handle. Using a rubber mallet drive sleeve over end of handle until holes line up. Drive spring pin into holes. NOTE: The U-joint and handle shaft are designed for a tight fit. A coating of grease will ease this process. See Illustration 19. B. HANDLE EXTENSION/CRANK HANDLE Insert crank handle into handle extension (select 1 of 4 holes) and align holes to bolt together. The extra holes are for handle length adjustment later if needed. See Illustration 19. Handle Extension Spring Pin Sleeve End Of U-Joint ILLUSTRATION 19 Crank Handle Handle Extension Apply Coat Of Grease Here Around Tube -12-

24 STEP 10: CRANK HANDLE ASSEMBLY (Continued) INSTALLATION INSTRUCTIONS Align Grooves And Insert Drive Cartridge As Shown Mark And Drill 5/16 Hole As Shown For Drive Rivet C. At rear of roll tube align grooves on drive cartridge with grooves on roll tube so the notch on cartridge faces out. Then insert cartridge into roll tube. Use the notch as a guide and measure in a straight line 2 inches in as shown. Make a mark and drill 5/16 hole through 1st layer of roll tube and cartridge. Then insert drive rivet, make sure it is fully seated and set with hammer. See Illustration 20. Orientate Drive Cartridge With Notch Facing Out ILLUSTRATION 20 Optional Rear Cord Return Kit 2 Insert Rivet, Fully Seat It And Set With Hammer D. For tarp system with OPTIONAL rear roll return, pull collar on cord down and slide it onto roll tube. See Illustration 21. Then with handle positioned so it will hang straight up and down, slide U-joint splines over splines on roll tube. Insert wire lock pin to secure handle. Tip: Applying grease to splines enables easier handle removal to adjust and set tarp tension when needed. Collar Apply Grease To Splines Wire Lock Pin FOR OPTIONAL REAR CORD KIT ONLY Apply Grease To Splines ILLUSTRATION 21 ILLUSTRATION 22 Wire Lock Pin FOR STANDARD CRANK KITS

25 E. Handle length should be about 18 above ground when hanging straight down. To adjust, remove bolts and slide lower portion of handle up or down inside upper handle and select hole location closest to 18 and rebolt. See Illustration 23. NOTE: On grain carts, crank roll tube up tight under latch plate, hold and bring handle straight down to grade. There should be about 6 inches of clearance from handle to grade. Adjust handle length if needed. Handle Length Adjustment Bolt Roll Tube And Handle Must Be 90 On Slant Back Boxes Roll Tube Bunji Collar VIEW IF ON SLANT BACK BOX ILLUSTRATION

26 INSTALLATION INSTRUCTIONS STEP 11: MOUNTING PINLESS HANDLE HOLDER A. HANDLE HOLDER Using crank, turn roll tube up (counter clockwise) until it is firmly secured under latch plate. Bring crank arm Crank Holder down toward box to full vertical And Mount position. Hold crank arm firmly with Safety/ both hands and lift it toward center Operating of box, until you find location you Decal want to mount crank holder bracket. The pinless handle holder should be located above handle portion of crank. When location for crank holder has been designated, allow roll tube to hang loose and assemble and mount holder to box. See Illustrations 24 and 25. ILLUSTRATION 24 NOTE: For stainless steel kits see page 3 for bolting procedures Holder Bracket 3/8 x 1 Self Threading Screw Crank Handle In Holder NOTE: For Grain Carts, refer to single sheet instruction on mounting handle holder extension. Pinless Crank Holder Spacer 1/2 X 1 Bolt ILLUSTRATION 25

27 STEP 12: ATTACH SAFETY/OPERATING DECAL A. OPERATING DECAL With crank handle placed in holder to secure it, locate the spot for the ATTENTION operating decal. This sticker must be placed in a visible location near handle holder on vehicle or all warranties are void! For warranty claims, provide serial number shown on this decal. STOP WARNING STICKER -14-

28 INSTALLATION INSTRUCTIONS STEP 13: HOOK-UP FRONT ROLL RETURN (At rear on electric kits) NOTE: For stainless steel kits see page 3 for bolting procedures Path of Cord 1 2 Bunji Guide 3/8 x 1 Self Threading Screws (2x) Corner Bunji Guide Protective Cord Cover Cord Cover A. Place bunji guide 1/2 back from end cap/latchplate. Mark and drill two 5/16 holes. Fasten guide with two 3/8 x 1 self threading screws. ILLUSTRATION 26 C. Cycle tarp through open and closing several times. Make adjustments if needed. NOTE: Before installing, hold bunji guide at location and inspect path of cord. Bunji cord should follow a natural path on top of end cap without interference from edge of tarp or wind deflector on end cap. If any sharp edges, burrs or corners interfere with path of cord, remove where needed.

29 STEP 14: TUBE STOP CLIP A. At ONE of the tarp stops, install 2 Phillips Head self drilling fasteners next to tarp stop body, one at each side. Run self drilling fasteners through the tarp and into fixed tube. NOTE: For stainless steel kits, drill a 1/8 pilot hole and use a nylon spacer with each fastener. See diagram and tip below. IMPORTANT NOTE: THESE FASTENERS PREVENT TUBE AND TARP SYSTEM FROM SLIDING BACK WHEN RAISING BOX OR FROM ROAD VIBRATION. Side View End View For electric operated tarp instructions go to step 16. ILLUSTRATION

30 INSTALLATION INSTRUCTIONS STEP 15: TARP TENSION ADJUSTMENT A. Before setting tarp tension, check orientation of U-Joint and wire lock pin. First make sure that U-Joint is in correct position for maximum strength when locked at 90 degree angle as shown in diagram at right. Make correction if needed. CORRECT INCORRECT U-Joint B. Next make sure that wire lock pin is in correct position to encompass around spline shaft as shown in diagram at right. Make correction if needed. CORRECT Wire Pin Lock INCORRECT

31 STEP 15: TARP TENSION ADJUSTMENT (Continued) C. To test tension - start with tarp hanging loose down along side of box. Hold crank firmly with both hands and turn roll tube closed up under latch plate and bring crank handle down vertical to ground. Then tighten tarp by lifting handle up toward handle holder and place it in holder. NOTE: Normally an 8 ft. handle is adjusted to 25 lbs. of lift. For initial tarp installations when lifting at the end of an 8 ft. long handle, it should take about 30 lbs. of lift to place it in the handle holder. (See chart for normal tension settings for other handle lengths and add about 5 lbs. extra at initial tarp installation.) D. To adjust tension - remove U-Joint from spline shaft, rotate it one groove and replace it on to shaft. Then secure with lock pin. Turn roll tube tight as described above. Repeat procedure until correct tension is acquired. NEVER OPEN OR CLOSE TARP WITHOUT U-JOINT SECURELY FASTENED TO SPLINE SHAFT WITH WIRE LOCK PIN. REPLACEMENT DECALS ARE AVAILABLE THROUGH AGRI-COVER, INC. OR AGRI-COVER DEALERS. E. SAFETY DECALS - Safety and operating procedure decals that come with this kit are provided for YOUR SAFETY. They should be kept clean at all times. Replace any decal that is worn, damaged, painted over, or unreadable. -16-

32 MANUAL CRANK OPERATING INSTRUCTIONS CLOSING FROM OPEN POSITION OPENING FROM CLOSED POSITION 1. Lift crank arm up out of crank retainer. 2. Bring crank arm up to a comfortable position and crank tarp open. 3. Bring crank arm down to a vertical position and lift it up into crank retainer. OPEN TARP when loading or unloading box. Unloading box with tarp closed will create a vacuum which could cause damage to tarp system. CLOSE TARP when transporting or storing. A closed tarp will extend the life of your tarp system.

33 INSTALLATION INSTRUCTIONS STEP 16: UPPER PIVOT ARM AND MOTOR (Continue here for electric operated tarps.) A. Assemble motor to bracket on upper pivot arm. Use three bolts with lock washers as shown. Leave motor cover off for now. Then locate lower pivot arm mounting bracket and lower pivot arm and proceed to next step. Bolt Lock Washer Upper Pivot Arm Electric Motor ILLUSTRATION

34 INSTALLATION INSTRUCTIONS STEP 17: LOWER PIVOT ARM AND PIVOT POINT A. PIVOT POINT LOCATION Locate pivot point on outside of box for lower pivot arm about 36 down from bottom of end cap at center of box. Mount pivot arm bracket to a solid area on box. Use holes in bracket to mark location and drill a 5/16 hole at each mark. Mount bracket with 3/8 x 1 self threading screws. Align hole in lower pivot arm with hole in bracket and turn 1/2 x 1 flanged head bolt into lock nut welded on back. Leave bolt just loose enough for arm to pivot freely. See Illustration 29. INSTALLATION TIP: Some vehicles may have obstructions that require moving the pivot point up higher than normal or even to the rear of the box. To do this the top pivot arm must be cut shorter. DO NOT CUT SHORTER THAN /8 Self Threading Screws Upper Pivot Arm Lower Pivot Arm Cable Ties Pivot Arm Bracket 1/2 of Box Width NOTE: For stainless steel kits see page 3 for bolting procedures 1/2 x 1 ILLUSTRATION 29

35 STEP 18: MOTOR ADAPTER AND ALIGNMENT A. MOTOR ADAPTER At front of roll tube, slide motor adapter onto tube. Slide bunji collar over motor adapter. See illustration 30. Do not drill or bolt to roll tube yet. B. MOTOR TO ROLL TUBE Position upper pivot arm with motor over the top of lower pivot arm. Hold onto motor and slide drive shaft into motor adapter on roll tube. Turn adapter by hand until its hole aligns with hole in motor shaft. Insert bolt and tighten with lock nut. C. SQUARE ALIGNMENT Adjust pivot arms to be square with roll tube by sliding motor with adapter forward or backward on roll tube - if not square motor will bind and wobble during operation. Inspect travel line of motor and arms to be clear of obstructions across front of box when opening and closing. Note: Bunji cord should NOT ride on top of cap - it should travel in front of cap as roll tube opens. Photos at right show a properly aligned system. Now drill hole in roll tube and bolt motor adapter tight. 90 IMPORTANT: VISUALLY INSPECT THE CLEARANCES OF THE MOTOR PIVOT ARMS, AND WIRING TO MAKE SURE THEY HAVE A CLEAR PATH TO OPERATE. IF THERE ARE OBSTRUCTIONS MAKE ADJUSTMENTS NOW. Bunji Cord ILLUSTRATION 30 Bunji Collar -18-

36 INSTALLATION INSTRUCTIONS STEP 19: ELECTRIC WIRING ROUTING A. WIRE ROUTING At front of box, bring 6 gauge wire up to pivot point, loop it around and leave slack for movement. Continue with wire along pivot arms sufficient to reach motor connections. Use nylon cable ties to hold wire to upper pivot arm. Do not connect wires to motor yet. Next, select best routing for 6 gauge wire along frame towards cab near existing wire harness and up to battery. See wire schematic on page Gauge Double Strand Wire (From Solenoid To Tarp Motor) Stop Warning Sticker 14 Ga. Wire From Switch To Solenoid Caution/Operating Decal Solenoid HD Dual Pole Connector Rocker Switch Inside Cab Circuit Breaker 40 Amp Caution/Operating Decal 6 Gauge Double Strand Wire (From Battery To Solenoid)

37 STEP 20: ELECTRIC CONNECTOR INSTRUCTIONS NOTE: For farm trucks with hoist, run wire to rear around hoist pin and back to front of box. (There will be no plug connection.) Thread Cutting Bolt 2X if unable to use nut behind frame drill 1/4 hole and turn thread cutting bolt into frame A. DUAL POLE CONNECTOR Mount plug connector to suitable location on semi tractor, adjacent to existing plugs. Mount socket to suitable location on trailer. Prep wires by stripping off insulation as needed. On off as needed Strip wire insulation wires at socket, slide heat shrink tube over wire, attach ring terminals and apply heat to shrink tubes. Bolt terminals tight. On wires at plug, insert bare wires into plug tubes and secure with set screws. See diagram at right for detailed assembly. ILLUSTRATION

38 STEP 21: MOUNTING SOLENOID INSTALLATION INSTRUCTIONS A. SWITCH LOCATION AND INSTALLATION. Select convenient location in cab to mount switch bracket with two self drilling screws through slots in back of bracket. Route 14 ga. wire from switch to location of solenoid at 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. Push switch into mount bracket until it snaps (locks) onto bracket. See Illustration 32. Front Of Bracket Black To Open Green To Center White To Close NOTE: Always mount Rocker Switch in convenient location inside cab. Switch is not designed for outdoor use. Self Drilling Screw ILLUSTRATION 32

39 B. PREPARE WIRE FOR CONNECTOR TERMNALS. The illustration at right shows terminal ring sizes for heavy gauge wires connecting to battery posts, circuit breaker, motor terminals and solenoid terminals used in the following steps. Insulation is stripped of ends, heat shrink tubes are supplied for sealing and rubber boots are supplied for solenoid terminals. Before cutting wires, go to next page and mount solenoid as suggested. Then always measure wire lengths to ensure you have plenty of wire when cutting and attaching terminals. Illustration 33. 1/2 Eyelet For (+) Battery Post 3/8 Eyelet For (-) Battery Post 5/16 Eyelet For Circuit Breaker And Motor Terminals 1/4 Eyelet for Solenoid Terminals 5/8 Rubber Terminal Boots For Solenoid Connections Only Typical For All Heavy Gauge Wire Eyelets Typical Heat Shrink Tube For All Heavy Gauge Wire Connections ILLUSTRATION

40 INSTALLATION INSTRUCTIONS STEP 21: ELECTRIC MOUNTING INSTRUCTIONS (Rocker Switch/Solenoid) (Continued) C. SOLENOID. Mount solenoid in protected area near battery using (2) #2 x 1 self drilling Phillips screws. Continue with wiring connections at right. 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. Prep end of green wire from switch with ¼ ring terminal. HEAVY GAUGE WIRES. Prep end of black and red heavy gauge wires leading from motor and battery with heavy gauge ¼ ring terminals, heat shrink tubes and rubber boots for (4) solenoid studs. Attach wires to solenoid studs as shown. Note the light gauge jump wire leads through same rubber boot with black (-) wire from battery. The green wire from switch leads through same rubber boot with red (+) wire from battery. When tightening nuts on terminals always hold base nut while tightening top nut. Do not over tighten. CIRUIT BREAKER. Install circuit breaker in line on red (+) positive wire close to battery using 5/16 ring terminals and heat shrink. BATTERY. Prep end of heavy black wire for battery (-) negative post with heat shrink tube and 3/8 ring terminal. Prep end of heavy red wire for battery (+) positive post with heat shrink tube and ½ ring terminal. Do not connect wires to battery now. 3/8 Terminal 1/2 Terminal HEAT SHRINK TUBE (TYPICAL) BLACK CIRCUT BREAKER INSTALLATION TIP: See Rocker Switch Wire Schematic page 22. RED ALLWAYS HOLD BASE NUT WHILE TIGHTEN- ING TOP NUT NOTE: DO NOT OVER TIGHTEN JUMP WIRE RED 1/4 Terminal #2 SELF DRILLING PHILLIPS HEAD SCREW WHITE ILLUSTRATION 34 5/16 Terminal at motor BLACK GREEN BLACK

41 STEP 22: MOTOR CONNECTIONS INSTALLATION INSTRUCTIONS A.WIRING AT MOTOR. Prepare wire ends for motor terminals with heat shrink tubes and 5/16 ring terminals. Attach BLACK wire to terminal 1 on motor. Attach RED wire to terminal 2. Always hold base nut while tightening top nut. At battery, first attach RED wire to positive (+) post. Then attach BLACK wire to negative post (-). Check power by activating switch to open position and closed position. If motor turns tarp correctly, attach cover. If motor turns tarp in wrong direction, reverse black and white14 gauge wires at solenoid. Check system again. When done, make sure all connections are secure and all wires are clear of sharp edges. Always Hold Base Nuts While Tightening Top Nut Heat Shrink Tube Red Wire Flat Washer Flange Nut ILLUSTRATION 35 Motor Cover -21-

42 SOLENOID PARTS LIST Qty. Part # Description Terminal, Ring 1/4 6 GA Non-Insulated Cover, Terminal, 8-2 GA Rubber Boot Screw, PH Pan Head #2 Self Drilling, X1 Zinc PL Terminal, 1/4 14GA Push on Female Insulated Terminal, Ring 1/4 14 GA Insulated Solenoid GRP (includes jump wire) Wire ASM, Jumper Terminal Ring 1/2 6 ga. Terminal Ring 3/8 6 ga. Terminal Ring #10 6 ga. WIRE SCHEMATIC DIAGRAM

43 PARTS LIST FOR ELECTRIC KITS Qty. Part # Description Phillips Self Drilling Screw #14 x Eyelet Terminal Ring 6 ga. x 5/ Hex Nut Serrated Flg. 5/ Rocker Switch 12v 10 Lin. Ft Wire, 3 Conducter, 14 ga /16 ID Rubber Grommet Switch Mounting Bracket Socket, Dual Pole Connector Plug, Dual Pole Connector Lower Pivot Arm Upper Pivot Arm Circuit Breaker, 40 Amp Nylon Cable Ties (Kit) PARTS LIST FOR ELECTRIC KITS Qty. Part # Description Electric Motor Mount Bracket Pivot Arm /2 x 1 Pivot Bolt Self Lock Nuts Electric Motor Adapter O-Ring/Bunji Collar Bunji Corner Guide /8 x 2-3/4 Bolt /8 Lock Nut Bunji Cord ga. Double Strand Cable (Spec. Lgth.) Heat Shrink Kit Electric Operating Decal ELECTRIC MOTOR OPERATING INSTRUCTIONS STEP 1: CLOSING FROM OPEN POSITION Push switch to the CLOSED position and hold. Visually view tarp position and release switch when tarp is fully closed. STEP 2: OPENING FROM CLOSED POSITION Push switch to the OPEN position and hold. Visually view tarp position and release switch when tarp is fully open. NOTE: Holding switch when roll tube has reached the end of cycle and is no longer turning will trip the automatic circuit breaker. After breaker resets, switch will activate motor again. To reduce unnecessary strain on tarp components, release switch when rolling tarp reaches fully open or fully closed position. OPEN TARP when loading or unloading box. Unloading box with tarp closed will create a vacuum which could cause damage to tarp system. CLOSE TARP when transporting or storing. A closed tarp will extend the life of your tarp system. -22-

44 SAFETY INFORMATION n Always use adequate caution when operating tarp. n Make sure tarp is open before unloading or loading. n Make sure nobody is on or near tarping system before and during operation. n Do not operate tarp with box hoisted in an elevated position. n If tarp is covered with snow, its removal is important before operating. n End caps must be free from grain that may be piled on them. Grain should not be heaped higher than end caps. n Do not operate this vehicle at highway speeds, while tarp system is in the open position. n Instruct everyone who will operate this tarp the correct procedures of doing so, or have them read this entire manual. INSPECTION AND MAINTENANCE n Periodic preventive maintenance should be practiced. Inspect tarp and hardware often for abrasions or loosened bolts that may need adjustment and/or repair and adjust tension whenever needed. Tarp must be kept to a recommended pounds of tension or excessive tarp wear may occur. n If installed correctly, tarp should always operate as well as when first installed. If tarp does not pass this simple inspection, make all appropriate repairs or adjustments immediately before serious damage occurs. n Routinely grease zerk on crank handle U-joint. n Periodically remove handle and apply grease to splines. n Bunji cord recoil memory will typically take longer if left open for a long period of time or when operated in cold weather. SAVE THIS MANUAL FOR FUTURE REFERENCE

45 -23-

46 PARTS DIAGRAM (See page 25 for descriptions)

47

48 EZ-LOC PARTS NO. DESCRIPTION NO. DESCRIPTION NO. DESCRIPTION 1 Tarp Fabric 15 PVC Tube ( 1 open end, 1 swaged end) 29 Bow Pocket 2 1" Stationary Tube 16 Flat Washer 30 Bow Extension 3 Drive Rivet, 3/16" (stationary tube splice & tarp attacment) 4 Tube Stop Fastners (2-screws) (SST- 2 screws, 2 spacers) 17 Latch Plate 31 Bow 18 Corner Bunji Guide 32 Ridge Strap 5 Quick Release Tarp Stop Assembly 19 Crank Extension w/roll Pin 34 OPTIONAL Quick Release End Cap Bracket 6 5/16" x 3" Clevis Pin w/bow Tie Pin 20 5/16" x 1-3/4" Bolt w/ Nut 35 Handle Hodler Mount 7 3/8" x 1" Self Threading Screw 21 Crank Handle w/bolt and Nut 36 1/2" x 1" Flange Bolt 8 2" Aluminum Roll Tube 22 U-joint 37 Pinless Crank Holder 9 2" Aluminum Roll Tube Splilce 23 Lock Pin (for u-joint) 38 Operating Decal 10 Drive Rivet, 1/4" x 5/16" Countersink (roll tube splice) 24 Front End Cap 39 Crank Handle Warning Decal 11 Bunji Cord 11 ft. 25 Rear End Cap 40 Spacer 1/2" x 5/16" 12 Drive Cartridge Adaptor w/drive Rivet 26 EZ-LOC End Cap Decal 41 Protective Cord Cover 13 EZ-LOC Bunji Plug w/screw 27 OPTIONAL Angle Bracket For End Cap 14 PVC Tube ( 2 open ends) 28 End Cap Weather Seal

49 To order a replacement tarp find your tarps serial number where shown. Serial number is under the barcode on the decal at the rear of the stationary tube. -25-

50 ROLL TUBE DEFLECTOR (Optional) Roll tube deflectors fasten to side of box to keep roll tube from damaging paint on sides of trailer. Fasten with Phillips head self drillling screw. Use caution to avoid overtorqueing screw. Overtorqueing screw may damage deflector.

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55 /2 Terminal Ring 6 ga /8 Terminal Ring 6 ga /16 Terminal Ring 6 ga /4 Terminal Ring 6 ga #10 Terminal Ring 6 ga /4 Terminal Ring 14 ga /4 Female Terminal 14 ga /16 Terminal Ring 4 ga /4 Terminal Ring 4 ga #10 Terminal Ring 4 ga /2 Terminal Ring 4 ga /8 Terminal Ring 4 ga.

56 MANUFACTURER S LIMITED WARRANTY Agri-Cover, Inc. extends the following limited warranty on its EZ-LOC Roll-Up Tarp to the original retail purchaser: Agri-Cover, Inc. warrants its EZ-LOC Roll-Up Tarp to be free from defects in material and workmanship under normal use for one (1) year from date of purchase. ANY IMPLIED WARRANTY APPLICABLE TO THE EZ-LOC ROLL-UP TARP IS LIMITED IN DURATION TO ONE YEAR FROM THE DATE 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 performance 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. Warranty registration must be on file and/or proof of original purchase (detailed and dated receipt) required for warranty to be effective. Goods to be returned must have a pre-authorized 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. This warranty gives you specific legal rights and you may have other rights which vary from state to state. Agri-Cover, Inc. Customer Service Dept Hwy. 281 SE, PO Box 508, Jamestown, ND AGRI-COVER, INC. P.O. Box 508 Jamestown, ND :00 a.m. - 5:00 p.m., Central Time Monday through Friday, except holidays. COPYRIGHT 2011 AGRI-COVER, INC., ALL RIGHTS RESERVED Part Part No. No REV:N REV:O