REPLACING ROLTEC SPRING ARMS NOTICE TO INSTALLER: Even if familiar with hardware, read instructions prior to installation as improvements may be made without notice. Always handle components with care. If you have any questions or problems, call customer service. When done, these instructions must be given to the consumer. NOTICE TO CONSUMER: Before using this product, read instructions. Save these instructions for future reference. Questions? 800-233-4655 agricover.com
TABLE OF CONTENTS Tools Needed and Safety Information 2 Inspection and Maintenance 3 Front Arm Installation 4-11 Rear Arm Installation 11-18 Warranty Back Page PREPARATION TOOLS NEEDED Protective eyewear Tape measure Marking pencil 3/8 Electric drill #2 and #3 Phillips driver bit 5/16 Drill bit Center punch Impact wrench 9/16 Socket 9/16, 1/2, 7/16 and 3/8 Combination wrenches Heat gun Wire cutter and crimper Grinder Hammer SAFETY INFORMATION Always use caution when operating tarp. Ensure tarp is open before unloading or loading. Ensure people are clear of tarp system before and during operation. Do not operate tarp with box hoisted in elevated position. If tarp is covered with snow, remove before operating. End caps must be free from commodity that may be piled on them. Commodity should not be heaped higher than end caps. Do not operate the vehicle at highway speeds with tarp system in the open position. Instruct everyone who will operate this tarp on the proper procedures. Avoid direct pressure washer spray to electric motor and motor connections. Do not directly spray the electric motor and electrical connections with a pressure washer. California Proposition 65: This product contains or emits chemicals known to the state of the California to cause cancer, birth defects, and other reproductive harm. 2
INSPECTION AND MAINTENANCE Periodic preventive maintenance should be practiced. Inspect tarp system often for proper operation. Periodically inspect front and rear arms (and spiral springs) for loose or worn parts and replace as needed. Clean telescoping components for smooth operation.! CAUTION: Some lubricants attract dust, avoid using on telescoping components. 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. The worm gear is lubricated with 5 ounces of Mobil SHC 630 lubricant and sealed for life. Periodically grease zerk fittings and lubricate chain. Remove plastic plug to access chain inside gearbox. Grease zerk Lubricate chain (80W SAE gear oil) 3
FRONT ARM REPLACEMENT 1. DISCONNECTING MOTOR A. Unroll tarp to hang down on the latch plate side. Disconnect wire from battery. Then disconnect wire running from motor terminals. Pull wire through the arms. B. Remove clevis pin and cotter pin from drive cartridge. Pull motor shaft out of drive cartridge and lower arm toward ground to take tension off of arm.! CAUTION: Spring arm under pressure, requires two people for safe handling. Cotter pin Cotter pin Clevis pin 2. REMOVING MOTOR FROM EXISTING ARM A. Remove motor from existing arm by removing (4) bolts on back of gearbox. Save motor and bolts for installation on new arm. (4) Bolts Existing spring arm Motor 4
3. REMOVING SPRING ARM HARDWARE A. Remove retaining ring and washer at pivot mount of lower arm. Save these parts for installation of new arm. Washer Retaining ring Pivot mount 4. REMOVING FRONT ARM A. Slide front arm off of pivot mount. Remove (4) torsion springs, 3-3/4 carriage bolt, spacer bushing, nylock nut and (2) wear bushings. Save these parts for installation of new arm. Carriage bolt (2) Wear bushings Nylock nut Lower arm (4) Torsion springs Spacer bushing 5
5. CHECK PIVOT MOUNT DISTANCE Tip: Pivot mount may need to be moved, see below to determine if it needs to be relocated. A. Measure from top of end cap to center of pivot mount. If distance is not between 47-55, pivot mount will need to be relocated. If pivot mount does not need to be relocated skip to Step 9. End cap Pivot mount and support plate centered on box Measure down to center of pivot mount support plate 47 Min 55 Max Centerline of box Maintain 5 of clearance from obstructions below B. Use the following illustration for slant wall trailer installation. Measure down on slant wall as shown 47 Min 55 Max Maintain 5 of clearance from obstructions below 6
6. PIVOT MOUNT RELOCATION IF NEEDED Tip: For easier installation, park trailer on level grade and unhook tractor. A. Take pivot mount off by removing securing bolts (keep for later use). At front of trailer, align center point of pivot mount support plate with centerline of box. Measure down 47-55 from top of end cap and mark holes for drilling. Do this on both vertical and slant wall boxes. If unable to place at recommended location, pivot mount can be located higher on the box, which may lift tarp off box during operation. Make sure telescopic arm has a clear pathway to operate. NOTE: Pivot mount support plate should be attached to support braces when possible. Tip: Hold pivot mount support plate in position with centerline. Then mark hole locations in line with support braces using grooves on support plate as guide. End cap Pivot mount and support plate centered on box Measure down to center of pivot mount support plate 47 Min 55 Max Centerline of box Maintain 5 of clearance from obstructions below B. Use the following illustration for installation on a slant wall trailer. NOTE: On slant wall installs, hole pattern will tilt downward from measured centerline. Measure down on slant wall as shown 47 Min 55 Max Mark hole pattern locations Maintain 5 of clearance from obstructions below Pivot mount support plate WARNING: DO NOT DRILL HOLES YET! 7
7. INSTALLING SUPPORT PLATE 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 bolts, when possible use nuts on back of pivot mount support plate. NOTE: Bolt locations may vary from what is shown below based on location of support braces on trailer. 3/8 nut Pivot mount support plate Pivot mount needs to be centered on box 3/8 x 1-3/4 bolts Centerline of box IMPORTANT: Before proceeding make sure pivot mount is centered on box, and tighten all hardware. 8. BOLT PIVOT ARM TO PIVOT MOUNT A. With pivot mount relocated, secure 3-3/4 carriage bolt, spacer bushing and nylock nut from Step 4. Insert wear bushings then slide new arm assembly and existing torsion springs onto pivot mount. Tab on torsion springs must sit in groove in pivot shaft and hooks should be toward latch plate side. NOTE: Assemble while arm is hanging down without tension. Slide arm onto pivot mount Groove in pivot mount Torsion springs secured with carriage bolt, spacer and nut 8
9. SECURE NEW ARM ASSEMBLY A. Secure new arm assembly to pivot mount with existing washer and retaining ring from Step 3. NOTE: Assemble while arm is hanging down without tension. Slide arm onto pivot mount Groove in pivot mount Retaining ring Washer Torsion springs secured with carriage bolt, spacer and nut 10. ATTACHING MOTOR TO NEW ARM! CAUTION: Spring arm under pressure, requires two people for safe handling. A. Attach existing motor to new arm using existing hardware from Step 2. Add additional thread lock if needed. Torque to 18 ft-lbs. Existing bolts New spring arm Existing motor 9
11. ATTACHING MOTOR TO ROLL TUBE! CAUTION: Spring arm under pressure, requires two people for safe handling. NOTE: Once assembled, add grease to grease zerk for motor shaft. A. FRONT VERTICAL WALL TRAILER: Raise spring arm with motor and insert shaft into roll tube extension. Secure shaft to tube with cotter pin. Rotate tube as needed to align holes in tube with hole in shaft. Insert clevis pin and secure it with cotter pin, bend tabs to secure. End cap wind deflector Sleeve 90º Cotter pin Cotter pin Clevis pin Telescopic arm Insert motor shaft and drive cotter pin in first. A. FRONT SLANT WALL TRAILER: Raise spring arm with motor and insert shaft into roll tube extension. Secure shaft to tube with cotter pin. Rotate tube as needed to align holes in tube with hole in shaft. Insert clevis pin and secure it with cotter pin, bend tabs to secure. End cap wind deflector Sleeve 90º Cotter pin Cotter pin Clevis pin Telescopic arm Insert motor shaft and drive cotter pin in first. 10
12. CONNECTING WIRE TO MOTOR A. Reroute existing wire (running through new spring arm) to motor and receiver. On motor, black wire goes to terminal 1, red wire goes to terminal 2. Always hold base nut while tightening top nut on motor terminals. Torque to 42 in-lbs. On receiver, black goes to M1, red to M2. Secure boots on terminals. Also torque to 42 in-lbs. B. Once all wiring is complete, inspect travel paths of arms to ensure no interference. Make adjustments if needed. REAR ARM REPLACEMENT 13. REMOVING COLLAR FROM ROLL TUBE A. Remove screw holding outside collar on roll tube. Slide collar off of roll tube. Save collar and screw for installation of new arm. Remove and save screw. Collar 11
14. REMOVING ARM FROM ROLL TUBE A. Remove bolts that secure bearing wear tubes to arm flange. Slide outside bearing wear tube off roll tube. Save bearing wear tube and hardware for installation of new arm. Slide arm flange off roll tube, lower arm toward ground to relieve tension.! CAUTION: Spring arm under pressure, requires two people for safe handling. Bearing wear tube Existing spring arm 15. REMOVE SPRING ARM HARDWARE A. Remove retaining ring and washer at pivot mount of lower arm. Save these parts for installation of new arm. Washer Retaining ring 12 Pivot mount
16. REMOVING REAR ARM A. Slide rear arm off of pivot mount. Remove (4) torsion springs, 3-3/4 carriage bolt, spacer bushing, nylock nut and (2) wear bushings. Save these parts for installation of new arm. Carriage bolt (2) Wear bushings Nylock nut Lower arm (4) Torsion springs Spacer bushing 13
17. CHECK PIVOT MOUNT DISTANCE Tip: Pivot mount may need to be moved, see below to determine if relocation is necessary. A. Measure from top of end cap to center of pivot mount. If distance is not between 47-55, pivot mount will need to be relocated. If pivot mount does not need to be relocated skip to Step 20. End cap Pivot mount and support plate centered on box Measure down to center of pivot mount support plate 47 Min 55 Max Centerline of box Maintain 5 of clearance from obstructions below B. Use the following illustration for slant wall trailer installation. Measure down on slant wall as shown 47 Min 55 Max Maintain 5 of clearance from obstructions below 14
18. PIVOT MOUNT RELOCATION IF NEEDED Tip: For easier installation, park trailer on level ground and unhook tractor. A. Take pivot mount off by removing securing bolts (keep for later use). At rear of trailer, align center point of pivot mount support plate with centerline of box. Measure down 47-55 from top of end cap and mark holes for drilling. Do this on both vertical and slant wall boxes. If unable to place at recommended location, pivot mount can be located higher on the box, which may lift tarp off box during operation. Make sure telescopic arm has a clear pathway to operate. NOTE: Pivot mount support plate should be attached to support braces when possible. 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. End cap Pivot mount and support plate centered on box Measure down to center of pivot mount support plate 47 Min 55 Max Centerline of box Maintain 5 of clearance from obstructions below B. Use the following illustration for slant wall trailer installation. NOTE: On slant wall installs, hole pattern will tilt downward from measured centerline. Measure down on slant wall as shown 47 Min 55 Max Mark hole pattern locations Maintain 5 of clearance from obstructions below Pivot mount support plate IMPORTANT: DO NOT DRILL HOLES YET! 15
19. INSTALLING SUPPORT PLATE 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 bolts, when possible use nuts on back of pivot mount support plate. NOTE: Bolt locations may vary from what is shown below based on location of support braces on trailer. 3/8 nut Pivot mount support plate Pivot mount needs to be centered on box 3/8 x 1-3/4 bolts Centerline of box IMPORTANT: Before proceeding make sure pivot mount is centered on box, and tighten all hardware. 20. BOLT PIVOT ARM TO PIVOT MOUNT A. With pivot mount relocated, secure 3-3/4 carriage bolt, spacer bushing and nylock nut from Step 16. Insert wear bushings then slide new arm assembly and existing torsion springs onto pivot mount. Tab on torsion springs must sit in groove in pivot shaft and hooks should be toward latch plate side. NOTE: Assemble while arm is hanging down without tension. Slide arm onto pivot mount Groove in pivot mount Torsion springs secured with carriage bolt, spacer and nut 16
21. SECURE NEW ARM ASSEMBLY A. Secure new arm assembly to pivot mount with existing washer and retaining ring from Step 15. NOTE: Assemble while arm is hanging down without tension. Washer Slide arm onto pivot mount Retaining ring Groove in pivot mount Torsion springs secured with carriage bolt, spacer and nut 22. SLIDE NEW SPRING ARM ONTO ROLL TUBE! CAUTION: Spring arm under pressure, requires two people for safe handling. A. Raise new spring arm and slide onto roll tube. Slide bearing wear tube from Step 14 onto roll tube. Adjust rear spring arm 90 to roll tube and secure bearing wear tubes with hardware removed in Step 14. Do not over tighten. New spring arm 17
23. POSITION OUTSIDE COLLAR A. Position outside collar from Step 13 onto roll tube and position it 2 from bearing wear tube. Secure with #14 x 1 self-drilling Phillips screw removed in Step 13. Screw Outside collar 2 24. TEST OPERATION A. Reconnect battery and test operation. If motor runs tarp in reverse of open and close positions on switch, reverse wires at motor. 18
MANUFACTURER S LIMITED WARRANTY Agri-Cover, Inc. extends the following Limited Warranty on its ROLTEC Electric Tarp Conversion to the original retail purchaser: Agri-Cover, Inc. warrants ROLTEC Electric Tarp Conversion to be free from defects in 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. This Limited Warranty does not cover any failure due to accident, abuse, misuse, alteration, neglect, improper assembly or installation, improper maintenance or ordinary wear and tear. Agri-Cover, Inc. s sole obligation under this Limited 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. AGRI-COVER, INC. EXPRESSLY DISCLAIMS ANY AND ALL IMPLIED WARRANTIES OF MERCHANTABILITY, AND THERE ARE NO WARRANTIES WHICH EXTEND BEYOND THE LIMITED WARRANTY DESCRIPTION CONTAINED HEREIN. For warranty, have your serial number ready and call our Customer Service Department at 800-233-4655 to determine if only a replacement part is needed or if the conversion needs to be returned for inspection and repair. 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, Inc. will pay freight to return goods to sender. This Limited Warranty gives you specific legal rights and you may have other rights, which vary, from state to state. For replacement parts shop at tarpreplacementparts.com or call Customer Service at 800-233-4655. Agri-Cover, Inc. Customer Service Dept PO Box 508 3000 Hwy 281 SE Jamestown, ND 58402 Phone: 800-233-4655 ROLTEC is a registered United States trademark of AGRI-COVER, INC. Hours: 8:00 am - 5:00 pm CST Monday through Friday, except Holidays 2017 AGRI-COVER, INC. ALL RIGHTS RESERVED. Product subject to change without notice. Patents: agricover.com/patents. 050417 90321_B