Installation Instructions ELECTRIC CONVERSION KIT 3 ALUMINUM ROLL TUBE IMPORTANT: This Electric Conversion Kit has been designed for systems with a 3 aluminum roll tube. It is assumed that the tarping system is already in place on the trailer. These instructions outline how to place the electric system and the rear return system on the trailer. NOTE: A rivet kit has been provided to attach the tarp if needed. The silver rivets are to be used to attach the tarp to the stationary tube and the black rivets are to be used to attach the tarp to the 3 roll tube. NOTICE TO INSTALLER: It is recommended you take the time to read these instructions carefully before installing or using this Electric Conversion Kit. Often improvements are made without prior notice. Always handle components with care to avoid personal injury or damage to components. When done, these instructions must be given to the end user. NOTICE TO END USERS: Read these instructions and understand this Electric Conversion Kit before using it. Store these instructions for future use. Tested. Trusted. Guaranteed.
Table of Contents Inspection, Maintenance... Page 2 Safety and Operating Instructions... Page 3 Tools for Installation... Page 3 Installing Electric Conversion... Pages 4-22 Installing Electrical Parts... Page 20 Warranty... Back Page Inspection and Maintenance Periodic preventive maintenance should be practiced. Inspect tarp system often for proper operation. Periodically inspect front arm (and spiral springs) and cable return for loose or worn parts and replace as needed. 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 motor gearbox 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 gear box. Grease Zerk Chain lube (80W SAE gear oil) 2
ARM UNDER SPRING PRESSURE! Safety NOTE: If original decal becomes damaged or missing on arm, order replacement decal part number 70863. ARM IS NOT A STEP. READ MANUAL THOROUGHLY BEFORE DISSASEMBLING SPRING ARM. FAILURE TO DO SO COULD RESULT IN SERIOUS INJURY OR DEATH. MANUALS AVAILABLE AT AGRICOVER.COM PN 70863 ATTENTION: When performing maintenance procedures on spring arm, note that arm is under spring pressure. Always use caution and assistance from another person if disassembly is required. 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 Push 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 Push 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. IMPORTANT: Electric tarp system is equipped with a modified reset 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. Protective eyewear Tape measure Marking pencil 3/8 electric drill #2 and #3 Phillips driver bit 5/16 drill bits Center punch Impact wrench Tools Needed 9/16 socket 9/16, 1/2, 7/16 and 3/8 Combination wrench Heat gun Wire cutter and crimper Grinder Hammer 3
1. INSTALLING PIVOT MOUNT - Front of the Trailer NOTE: If installing pivot mount on a slant wall trailer skip step 1A and proceed to step 1B. A. Secure both halves of pivot mount with (3) 3/8 x 1-1/2 carriage bolts and 3/8 nuts. 3/8 nut Pivot mount 3/8 x 1-1/2 carriage bolt B. Slide stainless steel square nuts into channels on support plate. Secure pivot mount to support plate using (4) 3/8 x 1 bolts, flat washers and lock washers threaded into the square nuts in the channel. Center pivot mount on support bracket and tighten all hardware. 3/8 square nut Pivot mount Pivot mount support plate 3/8 square nut 3/8 x 1 bolt Flat washer Lock washer 4
2. PIVOT MOUNT/SUPPORT PLATE LOCATION - Front of the Trailer TIP: For easier installation, park trailer on level grade and unhook tractor. 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. 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 located higher on the box, though arm 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 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 Slant wall trailer Centerline of box Maintain 5 of clearance from obstructions below 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 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! 5
3. INSTALLING SUPPORT PLATE - Front of the Trailer 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, 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. C L 3/8 nut Pivot mount support plate Pivot mount needs to be centered on box Pivot mount support plate bolted on box 3/8 x 1-3/4 bolts Centerline of box IMPORTANT: Before proceeding make sure pivot mount is centered on box. If needed loosen hardware and readjust pivot mount at this time. 4. BOLTING PIVOT ARM TO PIVOT MOUNT For vertical wall trailer use step 4A, for slant wall trailer use steps 4B and 4C. 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. A. Bolt pivot arm to pivot mount using (4) 3/8 x 1 carriage bolts and 3/8 nuts. Make sure keyway in pivot shaft is pointed down. NOTE: Carriage bolts may be installed from back side of pivot mount if needed. Pivot mount 3/8 x 1 carriage bolts 3/8 nuts Pivot mount support plate Keyway in pivot shaft pointed down Pivot arm 6
4. BOLTING PIVOT ARM TO PIVOT MOUNT (Continued) Use steps 4B and 4C for installation on slant wall trailer B. Bolt pivot arm to slant bracket using (4) 3/8 x 1 carriage bolts and 3/8 nuts. Make sure notch in pivot shaft is pointed down and slant bracket has wide side up. NOTE: Carriage bolts may be installed from back side of slant bracket if needed. 3/8 nuts 3/8 x 1 carriage bolts Slant bracket, wide side up Pivot arm Keyway in pivot shaft pointed down C. Bolt pivot arm with slant bracket to pivot mount using (3) 3/8 x 1 carriage bolts, (3) 3/8 x 1-1/2 carriage bolts and 3/8 nuts. Make sure notch in pivot shaft is pointed down and wide side of slant bracket is up. Leave bolts loose for now. (3) 3/8 x 1 carriage bolts 3/8 nuts Pivot mount support plate Pivot arm bolted to slant bracket, wide side up and keyway pointed down (3) 3/8 x 1-1/2 carriage bolts 7
5. INSTALLING DRIVE CARTRIDGE 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. Front end of roll tube Protective sleeve Protective sleeve Drive cartridge Vinyl cap 8
6. VERTICAL ALIGNMENT OF MOTOR ARM NOTE: Arm is under pressure. Requires two people for safe installation. Vertical Wall Front Slant Wall Front 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. 7. CONNECTING MOTOR/GEAR BOX TO DRIVE Protective sleeve #12 Phillips head screw Roll pin Apply grease to motor shaft. Raise arm with motor up and insert shaft into drive cartridge. Secure shaft to tube with roll pin. A clevis pin is installed later. Align center of sleeve to travel over top of wind deflector (See photo A in Step 8). Secure with #12 Phillips head screw. 9
8. SQUARING MOTOR ARMS WITH ROLL TUBE Wind deflector A. Square the motor pivot arm with roll tube by adjusting the drive cartridge in or out as needed. NOTE: Trim cutting the end of the roll tube shorter may be necessary in some cases. 90 Protective sleeve 6 1/2 B. After pivot arm is squared with tube, measure along side of tube, 180 degrees opposite of rope channel, and mark 6-1/2 in from beginning of drive cartridge. 180 o Set 5/16 drive rivet C. Drill 5/16 hole through roll tube and first wall of cartridge inside of tube. Insert 5/16 x 9/32 drive rivet. Make sure rivet is fully seated. Set with hammer. 10
4-1/4 9: TRIM EXISTING LATCH PLATE - Rear of Trailer Make mark on latch plate Remove bolt to use in step 9B A. The latch plate will need to be shortened to accommodate the roller guides. Measure 4-1/4 in from end of latch plate and make mark. IMPORTANT: Ensure tarp will still rest on latch plate. 1 Cut latch plate at mark and remove all sharp edges Drill 5/16 hole centered on groove and secure with 3/8 x 1 self threading bolt from step 9A B. Loosen latch plate from box and make square cut on latch plate at mark made in step 9A. Remove all sharp edges and burrs to protect tarp. Refasten latch plate to box. Measure in 1 from cut end and use small groove line on latch plate as center point to drill 5/16 hole and fasten with 3/8 x 1 self threading bolt from step 9A. 11
10: ASSEMBLING / PLACING ROLLER GUIDE Roller Clevis pin Cotter pin A. Place roller with a flat washer on each side into the roller bracket. Line up holes and insert clevis pin through bracket, washers and roller. Secure clevis pin with a cotter pin. NOTE: Cotter pin should always be away from the tarp. Flat washer Lowest point of roller flush with or slightly above top of box 1/4 Drill 5/16 holes and secure with (2) 3/8 x 1 self threading bolts Mark holes to drill Roller bracket Roller guide Cotter pin away from tarp B. Position the roller guide 1/4 from cut end of latch plate. The lowest point of roller should be flush with or slightly above the top surface of the trailer. Roller bracket should not interfere with end caps. Mark the best bracket holes for your application. C. Drill 5/16 holes at each mark and secure roller bracket with (2) 3/8 x 1 self threading bolts. Kit comes with stainless steel hardware. If securing with stainless steel hardware, 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. 12
11. PREPARING SPRING BOX RETURN AT REAR OF BOX A. Unpack container with spring box. Lift both covers off of spring box 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 13
12. WRAPPING DRIVE LINE CORD ON ROLL TUBE A. At rear 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 REAR Box wall 14
13. LOCATING / MOUNTING SPRING BOX - Rear of the trailer NOTE: Installation is shown on smooth wall trailer. On trailers with ribbed walls, bolt spring box to ribs. If needed, optional brackets are available. See page 22 for details. A. At rear of trailer with roll tube hanging down, position spring box 10 to 14 down from roll tube clear of any interference and make mark at each end of spring box. B. Orientate spring box so pulley end is at same end as drive line cord. Align notches on spring box with lowest point of roller. Drive line cord needs to run near vertical (+/- 1/2 ). Adjust drive line cord on roll tube if needed. Adjust spring box to align notch with center of roller 10-14 C. Select solid bolting locations (such as rivet lines or ribs) for first two bolts near drive line (4 and 12 from front) and last bolt away from drive line. Knock out slotted slugs and make mark. For the three center bolts, select best location along laser etching of spring box and make mark at these locations. Before drilling, make sure all marks are at solid locations and notches on spring box align with center of roller. Drill 5/16 holes at marks. Roll tube 10-14 Spring box 10-14 Drive line Place last bolt through knockout Place three center bolts at laser etching Place first two bolts through knockouts 15
13. LOCATING / MOUNTING SPRING BOX (continued) D. After bolting locations are determined, on back side of spring box, apply self adhesive foam strips, one on top and one on bottom of each bolting location. Self adhesive foam strips Self adhesive foam strips Roll tube 10-14 Spring box 10-14 Drive line Button head bolt through knockout Button head bolts through holes at laser etching Button head bolts through knockouts E. Use a 3/8 x 1 self threading bolt to cut threads for button head bolts at all 6 locations. F. Realign spring box with holes and secure with a button head bolt and 3/8 flat washer at all 6 locations. With notches in line with cord, tighten bolts with a 7/32 Allen wrench. 16
14. INSTALLING 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) on ledge of spring box with spring loop towards middle of truck box. Hold and insert 3/8 x 2-3/4 bolt and spacer bushing, secure with lock nut, tighten until snug. Spring Spring Box 3/8 x 2-3/4 bolt 3/8 Bushing Lock nut 17
15. ATTACHING DRIVE LINE CORD TO SPRING/SETTING TENSION Pulley in spring box Start here Drive line cord Pulley block slot A. Route drive line around pulley in end of spring box, over and around pulley on end of tension spring and back towards pulley block slot in end of spring box. B. Pull cord snug tight and tie a knot on cord in line with V notch on spring box. Knot tied in snug tight cord V notch in spring box C. Pull cord through pulley block, stretching spring, and place knot in pulley block slot. Place knot in pulley block slot Pulley lined up with rectangular notch D. Check spring tension after the first open and close cycle of 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. 18
16. INSTALLING SPRING BOX DOORS 5/16 x 3 pin and cotter key A. Align holes in untabbed door with holes at end of box spring and insert 5/16 x 3 pin and cotter key. Bend tabs to secure. Repeat for tabbed door at other end. Untabbed door Keeper pin Tabbed door B. Swing doors closed with tab door overlapping opposite door. Both doors are designed with camber to close. Push firmly until both doors are closed. Insert keeper pin through doors and base of box. DOORS ARE SECURED with keeper pin. Always keep doors closed with pin in place while operating. 17. REAR TUBE CAP A. On back of trailer, install black cap over end of roll tube. 19
18. INSTALLING CONNECTOR SOCKET TIP: Dielectric grease is provided for electric wire connections. Use as needed. Dual pole mount bracket Connector socket Nut Lock washer A. Bolt connector socket to dual pole mount bracket using 5/16 x 1 bolts, flat washers, lock washers and nuts. Flat washer 5/16 x 1 bolt B. Before cutting wire, form a loop on arm that allows room for movement. Mark where to cut wire for connector socket at location on dual pole mount bracket. Cut wire, strip only enough insulation off to attach ring terminals and heat shrink tube. Attach wires to socket terminals. Heat shrink Stripped wire end Eyelet Square nut (2x) 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. Protective fabric Lock washer 3/8 x 3/4 bolt Dual pole mounting bracket 20
19. SECURING MOTOR TO ROLL TUBE Clevis pin Split cotter key Bend tabs on cotter key Using motor switch, align motor shaft hole with tarp shaft hole. Insert clevis pin and cotter key. Bend tabs to secure. Grease the zerk at this location. OPTIONAL EDGE TRIM NOTE: Some tall wind deflectors may cause increased friction and slightly reduce return spring function. For smooth return operation, trim air dam as needed. For tall air dams, end caps without hem or end caps that were trimmed; apply edge trim onto edge of front air dam from latch plate towards middle of air dam. Edge trim will not cover entire end cap. Repeat at rear end cap. Tarp stop side Front end cap Start applying edge trim here and work toward middle of end cap Latch plate side 21
OPTIONAL MOUNTING BRACKET FOR SPRING BOX INSTALLATION (Not included with tarp kits) If needed, call 800-233-4655 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 box on trailer with exterior structural ribs. 1. Position bracket on solid mounting surface of box wall (between ribs) so it fills gap between wall and spring box. 2. Mark bolting locations. Drill 5/16 holes. Fasten bracket to box wall with 3/8 x 1 self threading bolt (2x). Important: If mounting bracket to thin sheet metal, use extra nuts, flat 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 shown. Continue mounting remainder of spring box as specified in spring box installation section of the owner s manual. Lock nuts (2) Trailer rib Spring box Special bracket Button head bolts 3/8 x 1 self threading bolt (2x) 22
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MANUFACTURER S LIMITED WARRANTY Agri-Cover, Inc. extends the following limited warranty on its Electric Conversion Kit to the original retail purchaser: Agri-Cover, Inc. warrants its Electric Conversion Kit 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 ELECTRIC CONVERSION KIT 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 800-233-4655 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 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 PO Box 508 3000 Hwy 281 SE Jamestown, ND 58402 Phone: 800-233-4655 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. 051517 90967_G