AGRI-COVERTM SWITCH CONTROL INSTRUCTIONS Use these instructions in place of the rocker switch and solenoid sections in your roll tarp or ROLTECTM Electric Hopper Conversion instructions. Some installs require remote control instructions. If required, follow remote control instructions along with these instructions. 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 questions or problems call customer service. When done, these instructions must be given to the consumer. NOTICE TO CONSUMER: Before using AGRI-COVERTM Switch Control, read operating and safety sections. Save these instructions for future reference. FOR YOUR RECORDS DATE PURCHASED: WHERE PURCHASED: SERIAL NUMBER: (Located inside switch box cover) Questions? 800-233-4655 agricover.com
PREPARATION Unpack AGRI-COVER TM Switch Control components and clean mounting location. These instructions are applicable to the AGRI-COVER TM Switch Control, AGRI-COVER TM Tethered Switch Control and AGRI-COVER TM Switch and Remote Control kits. The main differences between the hardware is the Switch Control kit provides a toggle switch, Tethered Switch Control kit provides a tethered switch and jack and the Remote Control kit comes with remote control hardware and a tethered switch jack. The hardware appearance and components may vary, however, the installation instructions for the hardware is the same. COMPONENTS TOOLS NEEDED (1) AGRI-COVER TM Switch Control (1) Remote control (optional) (1) Tethered switch (optional) (1) 50 Amp breaker (1) Dielectric grease packet (2) Rubber grommets (optional) (4) 1/4 x 1-3/4 Hex bolts (4) 1/4 Flat washers (4) 1/4 Hex nuts (4) 1/4 Lock washers (4) Pieces of heat shrink (1) Cable tie 1/2 Wrench 1/4 Wrench Heat gun Marking pen Protective eyewear Slotted screwdriver Tape measure Wire crimper Wire stripper SAFETY INFORMATION Always use caution when operating tarp. Disconnect power before servicing system or electrical components. Ensure tarp is fully 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 piled higher than end caps. Ensure tarp system is fully open or fully closed before operating vehicle at highway speeds. Instruct everyone who will operate this tarp on the proper procedures. When internal access is not required, lockout control box to prohibit unauthorized or accidental access. Do not directly spray the electric motor and electrical connections with a pressure washer. 2
PARTS DIAGRAM Parts included: The diagram shows parts included in the AGRI-COVER TM Switch Control kit. Other parts shown in these instructions are supplied with separate kits or existing electric systems. NOTE: A tethered switch only installs on an AGRI-COVER TM Switch Control with a tethered switch jack. Also, the remote control only functions with AGRI-COVER TM Switch and Remote Control kits. Tethered switch jack Tethered switch jack Switch Control Tethered switch (compatible units only) (4) Butt connectors (4) Bolts, (4) washers, (4) lock washers and (4) nuts (2) Rubber boots Remote control (compatible units only) (2) Rubber Grommets Dielectric grease packet (4) Heat shrink (1) Cable tie 50 Amp breaker (4) Ring terminals Pre-installed heavy duty wires with butt connectors 3
WIRING DIAGRAM Switch Control Black wire (-) Butt connector M1 Red wire with white stripe (+) Motor terminal 1 Red M2 Motor wire (+) terminal 2 Black wire with white stripe (-) Butt connector Black wire (-) Optional dual pole connector 50 Amp breaker Red wire (+) Aux Bat (+) Battery NOTE: Use dielectric grease (packet included) at all electrical connections. NOTE: This electric system requires a 50 Amp modified reset circuit breaker. If breaker trips and does not reset, it may have detected a continuous short and will not reset until short is repaired. Disconnect battery and repair short. If installing this electric system on an existing unit, ensure there is a circuit breaker installed and operating properly. If breaker is missing or malfunctioning, replace it with a new 50 Amp modified reset circuit breaker. IMPORTANT: Operating system without a circuit breaker voids warranty. 4
1. ROUTING HEAVY GAUGE WIRE NOTE: There is ample heavy gauge wire supplied with each kit for standard installs. Before cutting wire, always preplan wire routing and make necessary adjustments as needed. NOTE: Use dielectric grease (packet included) at all electrical connections throughout installation. A. Route heavy gauge wires from battery to Switch Control and from Switch Control to tarp motor. Allow ample wire where cutting and mounting connections take place. See Figure 1 (box with hoist) and Figure 2 (semi-trailer box) on page 8. For terminal connections, prepare wire ends with terminals, heat shrink and rubber boots.! CAUTION: Do not connect wires to battery terminals at this point. 1/2 ring terminal for positive (+) battery post 3/8 ring terminal for negative (-) battery post #10 ring terminal for circuit breaker 1/4 ring terminal for motor terminals Typical for all heavy gauge wire eyelets 5/8 Typical heat shrink tube for all heavy gauge wire connections Rubber terminal boots for motor connections only 2. MOUNTING SWITCH CONTROL A. Mount Switch Control to a rigid location away from motor and other dangerous components. With power cords routed downward, use box as template to mark hole locations for drilling. Use bolts, washers, lock washers and nuts to finish mounting. IMPORTANT: Use at least 3 bolts to mount the box. Ensure bolts are mounted through the upper and lower screw holes. IMPORTANT: After mounting box, tighten strain relief fittings to ensure a weathertight seal. Strain relief and lower screw holes Upper screw holes Install box with cords routed downward 5
3. INSTALLING TETHERED SWITCH (Optional) NOTE: A tethered switch only installs on an AGRI-COVER TM Switch Control with a tethered switch jack. A. Mount Switch Control with tethered switch jack to a rigid location away from motor and other dangerous components. With cord routed downward, use tethered switch as template to mark hole locations for drilling. Use bolts, washers, lock washers and nuts to finish mounting. IMPORTANT: Before mounting the switch, ensure there is enough cord length for the plug to reach the switch jack. NOTE: Kits with tethered switches are supplied with (2) rubber grommets (compatible with 1.5 circular holes). In some installations, switch cables may route through holes cut in metal surfaces. Install rubber grommets in holes to provide cable protection. B. (Optional) Cut 1.5 circular hole into metal surface, file sharp/rough edges and burrs. Insert grommet into hole and then route tethered switch cable through metal surface. C. (Optional) If required, route tethered switch cable through rubber grommet. D. Connect tethered switch by inserting switch plug into switch jack, turn threaded nut clockwise until tight. IMPORTANT: After connecting tethered switch, tighten strain relief fitting to ensure a weathertight seal. 1.250 1.875 Screw holes Install tethered switch with cord routed downward 0.38 0.14 1.50 0.09 Insert switch plug into switch jack and turn clockwise to tighten 4. INSTALLING CAUTION/OPERATING DECAL A. When installing new tarp, attach tarp caution/operating decal to front driver side corner of truck box near Switch Control. 6
5. INSTALLING CIRCUIT BREAKER A. Attach red wires (with white stripe) to battery and aux circuit breaker connections. Seal with heat shrink then slip wires through rubber circuit breaker cover (not shown). See Wiring Diagram on page 4. Aux Battery Red wire with white stripe IMPORTANT: Ensure system has a 50 Amp modified reset circuit breaker installed as shown. Operating system without circuit breaker voids warranty. NOTE: If kit came pre-wired with 40 Amp breaker, remove and use 50 Amp breaker supplied in Switch Control kit. Red wire with white stripe Bat Aux Circuit breaker 6. WIRING HEAVY DUTY CONNECTOR (Optional) A. For trailer units with heavy duty connector, use terminals to attach wire to socket. Red wire to positive (+) terminal on socket and black wire to negative (-) terminal on socket. 7. ATTACHING BUTT CONNECTORS The Switch Control includes four pre-installed heavy gauge wires with butt connectors. Each butt connector attaches to a specific previously prepared wire (see Step 1). When attached, each combined wire connects to a specific motor terminal or battery post. Inserted cable Set screws Existing cable Perform the following to attach a wire to a butt connector: A. Position heat shrink over prepared heavy gauge wires (see Step 1). Connect heavy gauge wires to butt connectors as specified below: Switch Control black wire with white stripe to black battery wire Switch Control red wire with white stripe to red battery wire Switch Control black wire without white stripe to black motor wire Switch Control red wire without white stripe to red motor wire 7 Butt connector B. Verify wiring to Switch Control is as shown in Wiring Diagram on page 4. C. Verify wires are securely connected to butt connectors. Seal heat shrink over butt connectors and wires.
8. CONNECTING WIRES TO MOTOR AND BATTERY A. Double check all wire connections. Ensure all wires are connected properly (as shown in Wiring Diagram on page 4). Connect black M1 wire to motor terminal 1 Connect red M2 wire to motor terminal 2 NOTE: When attaching wires to motor terminals, always hold base nut while tightening top nut and torque to 42 in-lbs. Connect red battery wire to positive (+) battery post Connect black battery wire to negative (-) battery post B. Check system operation. If system operates in reverse, switch wires at motor and retest. 1 7 5 4 Figure 1 8 1 7 2 See Wiring Diagram on page 4. NOTE: Numbers indicate steps where items were installed. 5 Figure 2 6 8 2 4 8
OPERATING INSTRUCTIONS SAFETY INSTRUCTIONS Do not install or use this product without reading and understanding these instructions. Only allow people who know and understand the safety rules to use this system. Never allow children to operate or play with system. Only operate the tarp when the tarp is completely visible. Lockout electric system when you are not operating the tarp to avoid unintended operation. Disconnect power from the motor before servicing system. Do not directly spray the electric motor and electrical connections with a pressure washer. IMPORTANT: After control box and remote control (if supplied) are installed and setup, lockout control box with user supplied lock or included cable tie. Lockout slot Included cable tie OPENING AND CLOSING TARP With system on, either: A. Hold OPEN/CLOSE switch in OPEN position to roll tarp open. B. Hold OPEN/CLOSE switch in CLOSED position to roll tarp closed. IMPORTANT: When tarp movement stops or if an obstruction is in the path of the tarp, release the OPEN/CLOSE switch. Tethered switch open/close switch Open/close toggle switch 9
GENERAL TROUBLESHOOTING If system has a battery cutoff switch, ensure it is turned to ON position. Check all wiring components. A. Check positive (+) and negative (-) wire connections on vehicle battery. B. Retighten and re-crimp loose connections. C. Replace any corroded connections. D. Check all wire for worn or bare spots. E. Verify 12 volts or more come into the Switch Control while system is operating. Check power sources. Check for physical damage to any equipment. A. Check vehicle battery and charge, replace if required. A. Repair or replace if required. 10
TROUBLESHOOTING SWITCH CONTROL PROBLEM System will not operate with toggle switch (cannot hear a clicking noise from inside Switch Control). SOLUTION A. If system has a battery cutoff switch, ensure it is turned to ON position. B. Verify correct system wiring. See Wiring Diagram on page 4. C. Auto circuit breaker may have tripped. Wait several minutes and try again. If it still does not work, circuit breaker may have detected a continuous short and the short must be repaired. System will not operate with toggle switch (can hear a clicking noise from inside Switch Control, but nothing happens). A. Verify the Switch Control receives a minimum of 12 volts from battery. B. Verify at least 12 volts transmit to motor terminals. If the Switch Control receives 12 volts but does not transmit 12 volts, problems may be in Switch Control. C. Verify the motor receives at least 12 volts (use caution around moving parts). If the motor receives 12 volts and doesn t turn, the problem may be in the motor. D. If the Switch Control transmits 12 volts to the motor, and it does not receive 12 volts, problem may be wires connecting Switch Control to motor. The toggle switch operates the motor, but tarp motor turns freely and tarp does not move. A. Check pin connections in shaft between motor and roll tube. If missing, replace sheared bolt or pin with new clevis pin. B. Check tarp system for damaged or misaligned parts and correct as needed. C. Ensure tarp is free from obstruction. System does not operate with toggle switch. Motor engages but stalls and system does not turn. A. Check conditions and alignment of system. Ensure there are no broken components or obstructions. Refer to system s manual. 11
MANUFACTURER S LIMITED WARRANTY Agri-Cover, Inc. extends the following one (1) year Limited Warranty on its AGRI-COVERTM Switch Control to the original retail purchaser: Agri-Cover, Inc. warrants AGRI-COVERTM Switch Control to be free from defects in workmanship under normal use for one (1) year from date of manufacture unless accompanied by proof of purchase. This Limited Warranty does not cover any damage due to accident, abuse, misuse, alteration, neglect, improper installation, 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 AGRI-COVERTM Switch Control 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 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 Hours: 8:00 am - 5:00 pm CST Monday through Friday, except Holidays 2018 AGRI-COVER, INC. ALL RIGHTS RESERVED. Product subject to change without notice. 073118 2000097_F