WLH 09/19/16 111-0215 & 112-0215 607-0026 For technical support call us at (800) 368-3075 or visit our website at PullTarps.com.
TABLE OF CONTENTS ***Assembly*** Conversion Kit-Universal Super Shield ***Wiring, Conversion Kits & Diagrams*** Mounting Positions... 1 Electric Motor Wiring & Plug Assembly... 7 Removing Tarp & Welding System to Truck... 2 Electric Motor & Breaker Wiring... 8 Dimple Tailgate & Weld Tarp Return Ramps... 3 Special Instructions for ED Electric Conversion Kit... 9 Rope Storage Hook Installation... 4 Special Instructions for Electric Drive Conversion Kit... 11 Optional Flap Tarp, Rope and Hook Installation... Bungee Cord Installation... 5 6 Housing Assembly for 111-0215 USS with Electric Drive... 13 Housing Assembly 112-0215 UA with Electric Drive... 14 For technical support call us at (800) 368-3075 or visit our website at PullTarps.com. i
Mounting Positions Step 1: Determine the mounting position for your truck Fig. 1 - Fig. 6. Fig. 1 Fig. 2 Fig. 3 "A" Mount "B" Mount "C" Mount Fig. 4 Fig. 5 Fig. 6 "D" Mount "E" Mount "F" Mount "B" Brackets NOTE: Use optional "B" Brackets when mounting in position "B" and "E". 1
Removing Tarp & Welding System to Truck Step 2A: Before welding remove tarp to avoid damage (Fig. 7A). To remove tarp slide the tarp out of the slotted end of the housing and remove from work area. NOTE: Remove Tarp Before Welding. Step 2B: Weld system mounting bar to truck as shown in Fig. 7B. Fig. 7B Fig. 7A Weld Mounting Bar to Truck System Assembly Fig. 8A & 8B Fig. 8A Fig. 8B 2
Dimple Tailgate & Weld Tarp Return Ramps Step 3: Dimple Tailgate for Rope Guide. Check the top of the tailgate where your tarp goes over for any obstructions that may interfere with the tarp laying flat all the way across the tailgate area. WARNING: Sharp Edges May Cut Tarp. Measure tailgate to find center and mark. Heat at mark with torch until area is red hot. Use a 3/4 diameter solid bar and lay it on the spot and strike it a few times. A smooth indentation should be left that will keep the rope centered (Fig. 9 & 10). Fig. 9 Fig. 10 Step 4. Weld on Tarp Return Ramps The Tarp Return Ramps hold the pullrod in place once the tarp has been deployed. The ramps should be welded as high as possible. See (Fig.11 & 12 for your application). Make sure all rough edges are ground smooth. If you have a raised hinge you will need to add a Hinged Ramp Gusset (NOT SUPPLIED) see (Fig.13). Fig. 11 Tarp Return Ramp Fig. 12 Tarp Return Ramp Fig. 13 Tarp Return Ramp Hinge Ramp Gusset 3
Rope Storage Hook Installation Step 5: Mount the rope as low as possible. The rope should come straight down and wrap around the center hook and then coil off to the side (Fig.14). When tarp is not in use, space the hooks far enough apart to store the full length of rope (Fig.15). Fig. 14 Rope Storage Hooks Fig. 15 Note: Tarp must be retracted when dumping Rope Storage Hooks 4
Optional Flap Tarp, Rope and Hook Installation Parts: Tie Down Hooks (Steel or Alum.) Pull Down Hook Fig. 16 Fig. 17 Note: The Location Of The Tie Down Hooks Is Critical! Step 6: Flip the braided rope over the corner so that the flaps and tie down ropes hang over each side of the box. The number of tie down hooks vary depending on the length of your tarp. One pull down hook is included with your Pulltarp system. If needed. Use the hook to pull the braided rope and flaps over the side of the box. The tie down hooks must be positioned so that: 1. The tie down rope can be reached from the ground. 2. The bungee cord has to be stretched to reach the last hook (see Step 7). 3. The rope has no slack. 4. The tie down hooks are level with one another. Fig. 18 Fig. 19 CORRECT INCORRECT To ensure proper hook placement, first duct tape the rope to the box in place of the tie down hooks. Start with hook closest to the cab. 1. Position the first hook 6 (15.24cm) down and 12 (30.48cm) forward (toward the cab) from the first grommet (Fig. 16). 2. Position 2nd hook straight down from 1st grommet. This hook should be reached from ground 3. (Fig. 17). 4. Place middle hooks equal distances from grommet (Fig. 18). These hooks should be placed at the same height as the second hook. 5. Position last hook (closest to the tailgate) below the last grommet at the same height as the others (Fig. 19). 6. Weld hooks in place. 5
Bungee Cord Installation Parts: 2 Bungee Cords 2 Oval Compression Sleeves 1 Snap Clip Step 7: After side hooks are installed, the tie down rope must be installed and cut to proper length. It is important to get all of the slack out of the rope to prevent blowing and rubbing of flaps in windy conditions. Tarps with Tie Downs Fig. 20 Snap Clip Installation Fig. 24 2nd Snap Clip Fig. 21 Tailgate 1st Snap Clip To tighten, pull loose end of rope through the Oval Compression Sleeve (Fig. 20). Stretch the bun gee cord making sure all slack is taken out of the rope, crimp compression sleeve (Fig. 21). Top View Flip the rope back on top of the tarp, making sure to hold the bu gee at all times. The first snap clip is factory installed 5-6 from the pullrod. Open the clip and enclose the rope. Weave the second clip through the main pullrope where the ends of the bungee cords meet the main pullrope. Make sure the rope is taught when clipped (Fig. 24). Note: First snap clip should not be used on long wheel base belly dumps. 1. 2. 3. Tarps with Side Flaps Fig. 22 Fig. 23 Excess Rope Connect Bungee Cord to Rope 1. Thread braided rope through Oval Compression Sleeve. 2. Feed rope through the eye of the bungee cord. 3. Thread the rope back through the oval compression sleeve. Adjust for proper length. Crimp co pression sleeve. To tighten, pull loose end of rope through the Oval Compression Sleeve (Fig. 22). Stretch the bungee cord making sure all slack is taken out of the rope, crimp compression sleeve (Fig. 23). Note: Check for proper placement of rope through the last two hooks. Fig. 25 You may need extra rope to keep the side flap sywstem ground operated. If your application requires extra rope, the slack needs to be taken up by a taching the end of the bungee cord to an alternate hook (Fig. 25). 6
Electric Motor Wiring & Plug Assembly Fig. 26 * Trailer Connector Detail Step 9 - Wiring: Assemble the Quick Disconnect as shown (Fig. 27). Battery 5/8" Breaker Step 8 - Wiring: First, remove motor housing, then run the 6 ga. wire to both locations (motor & battery box) and attach to truck body (Fig. 26). Note: The wire must go beyond the pivot point. Caution: Make sure wire does not get pinched at the pivot. Fig. 29 Trailer Connector* Fig. 30 Terminal #1 Dump Pivot Switch Fig. 27 Wire Fig. 28 Step 11 - Attaching The Connectors (Motor): 1. Split the molded 6 ga. wire approximately 4" and strip the ends about 5/8" down. 2. Attach connectors (part # 514-0308) and crimp (Fig. 29). 3. Attach black wire to Terminal #1 on motor (Fig. 30). 4. Attach red striped wire to Terminal #2 on motor (Fig. 30). Note: Wire Cutters required. Pin Connector Spring Tab Step 10: Crimp or solder pin to wire (Fig. 28). Note: Make sure the pin snaps over the end of the spring tab. 6 ga. 1/4" Lug Connector (part # 514-0308) Terminal #2 7
Electric Motor & Breaker Wiring 6 ga. 1/4" Lug Connector (part # 514-0308) 5/8" To motor Step 12: 1. Mount the Control Box at tailgate. 2. Spilt the 6 ga. wire at the Control Box about 4" back and slip on rubber boots Red Boot (part # 514-0319) on red striped wire and Black Boot (part # 514-0317) on black wire (Fig. 31 & 32). 3. Strip wire about 5/8"and attach connectors (part # 514-0308) (Fig. 31). 4. Attach Red Striped wire to Motor (+) and Black wire to Motor (-) on Control Box (Fig. 32). Note: Do not over tighten nuts on connections! Fig. 31 Fig. 33 6 ga. #10 terminal ends (Part # 514-0307) Step 13: 1. Mount breaker in the battery box away from moisture. 2. Cut a section in the red 6 ga. wire that will run to the postive terminal on the battery. 3. Strip wire the ends about 5/8" and attach 6 ga. #10 terminal ends (part # 514-0307) (Fig. 33). 4. Attach to breaker. Battery Fig. 34 Battery Aux 14 ga. wire Light 30 Amp "Non Cycle" Breaker Note: Mount as close as possible to power supply. To reset, disconnect power. 6 ga. wire Fig. 32 Wiring Diagram (Fig. 34) - To Ground Motor Forward & Reverse Switch 6 ga. wire 14 ga. wire Motor 25 Amp Push To Reset Circuit Breaker Motor check out procedure: 1. Remove leads from motor & attach volt meter to the leads. 2. With the switch in the on position, the volt meter should read 12 volts minimum. If voltage is low recheck with engine running. Recheck wiring and connections (minimum 6 gauge wire must be used). 3. Return switch to the neutral position & reattach leads to motor. 4. Attach volt meter to leads at the motor. 5. With the switch in the on position and the leads attached, the volt meter should read 8.5 volts minimum. If voltage is low recheck with engine running. Recheck wiring and connections (minimum 6 gauge wire must be used). 6. Return switch to the neutral position and attach amp meter to leads at the motor. 7. With the switch in the on position, amp meter should read approximately 20 30 amps. Constant amperage reading of over 40 amps indicated binding in the system and/or low voltage. 8
Special Instructions for ED Electric Conversion Kit (Conversion Kit to add electric Drive to existing housing) Step A. Removing the Spring Remove the 7/16 bolt covering the access hole in the ratchet cover. Pull the tarp all the way out, secure to the tailgate. Insert a 3/8 x 3 bolt through the hole in the ratchet cover plate and into the groove in the roller tube (Fig. 1A). Step B. Remove Tarp from Housing Slide the tarp out of the roller tube through the slotted end plate (opposite side as ratchet) (Fig. 1A). Fig. 1A To To Disengage Lever, Increase Tension Remove Ratchet Lock & 1. Pull tarp out as far as Insert Screwdriver Here possible and tie off at tailgate 2. Remove Ratchet Lock. Turn ratchet nut clockwise 5 turns at at time. 3. Test operation and repeat steps 1 through 3 if necesary. To Decrease Tension: WARNING: 1. Remove Ratchet Lock. Place box Physical harm could occur if end wrench on all tension is not ratchet nut. Turn removed before ratchet nut slighty removing this plate. to the right and don t let go. 2. Insert screwdriver to disengage lever. Hold wrench with both hands and slowly unwind spring pressure. 3. When desired tension is achieved, remove screw driver allowing release lever to reengage ratchet gear. 4. Reinstall the Install Ratchet Lock here Rachet Lock. BY Ratchet Cover Plate Insert 3/8" Bolt Step C. Releasing the Spring Tension on the Roller Assembly 1. With a 3/4 box end wrench, turn the ratchet nut clockwise just far enough to relieve tension on the ratchet dog (Fig. 2A). 2. Place flat blade screwdriver on top of the ratchet dog to disengage it from the ratchet gear. 3. With both hands, turn the wrench counter clockwise to remove all of the tension from the spring. Do not let go of wrench! (be sure all of the tension has been released). Step D. Removing the Ratchet Cover Plate Remove the four screws from the ratchet cover plate and carefully take the plate off. Step E. Remove the Roller Tube Pull the entire roller tube assembly out the side of the housing (Fig. 3A). Step F. Removing the Spring Assembly 1. Remove the retaining screw from the end cap. 2. Place a piece of cardboard on the ground and hold the roller assembly vertically, with the ratchet assembly towards the ground. 3. Shake the roller assembly up and down above the cardboard to pop the end cap and spring assembly free from the roller tube (Fig. 4A). The card board is to protect the end of the spring shaft when it breaks free. Fig. 2A Fig. 3A Fig. 4A 9
Special Instructions for ED Electric Conversion Kit (Conversion Kit to add electric Drive to existing housing) Step G: Install Roller End Cap Before installing the Roller End Cap, the Roller Tube may need to be cut to to fit into the housing properly. Cut tube an additional 3/8 (Fig. 5A). Step H: Dimple the Roller Tube Once Roller End Cap is in Roller Tube, Dimple the end of the Roller Tube into the grove of the Roller End Cap with a flat head screw driver in three places (Fig. 6A). Fig. 5A Fig. 6A Dimple 3/8" Roller End Cap Roller Tube Step I: Universal Super Shield Install motor as shown below (Fig. 7A). Step J: Tarp Installation Slide Tarp into groove on Roller Tube and center (Fig. 8A). Part# EHW35 (3 REQ.) 5/16-18 X 1 HHCS BOLT Part# EHW34 (1 REQ.) 5/16-18 X 1 3/4 HHCS BOLT Fig. 7A Fig. 8A Part# P65/16LW (3 REQ.) 5/16 LOCK WASHER Part# P4AD1 (1 REQ.) ADAPTOR PLATE Part# 31 (1 REQ.) 5/16-18 NYLOCK NUT NOTE: See Switch Kit for Wiring Instructions. 10
Special Instructions for Electric Drive Conversion Kit Step A. Removing the Spring Remove the 7/16 bolt covering the access hole in the ratchet cover. Pull the tarp all the way out, secure to the tailgate. Insert a 3/8 x 3 bolt through the hole in the ratchet cover plate and into the groove in the roller tube (Fig. 1B). Step B. Remove Tarp from Housing Slide the tarp out of the roller tube through the slotted end plate (opposite side as ratchet) (Fig. 1B). Fig. 1B To To Disengage Lever, Increase Tension Remove Ratchet Lock & 1. Pull tarp out as far as Insert Screwdriver Here possible and tie off at tailgate 2. Remove Ratchet Lock. Turn ratchet nut clockwise 5 turns at at time. 3. Test operation and repeat steps 1 through 3 if necesary. To Decrease Tension: WARNING: 1. Remove Ratchet Lock. Place box Physical harm could occur if end wrench on all tension is not ratchet nut. Turn removed before ratchet nut slighty removing this plate. to the right and don t let go. 2. Insert screwdriver to disengage lever. Hold wrench with both hands and slowly unwind spring pressure. 3. When desired tension is achieved, remove screw driver allowing release lever to reengage ratchet gear. 4. Reinstall the Install Ratchet Lock here Rachet Lock. BY Ratchet Cover Plate Insert 3/8" Bolt Step C. Releasing the Spring Tension on the Roller Assembly 1. With a 3/4 box end wrench, turn the ratchet nut clockwise just far enough to relieve tension on the ratchet dog (Fig. 2B). 2. Place flat blade screwdriver on top of the ratchet dog to disengage it from the ratchet gear. 3. With both hands, turn the wrench counter clockwise to remove all of the tension from the spring. Do not let go of wrench! (be sure all of the tension has been released). Step D. Removing the Ratchet Cover Plate Remove the eight screws from the ratchet end plate and remove (Fig. 3B). Step E. Remove the Roller Tube Pull the entire roller tube assembly out the side of the housing (Fig. 3B). Step F. Removing the Spring Assembly A. Remove the retaining screw from the end cap. B. Place a piece of cardboard on the ground and hold the roller assembly vertically, with the ratchet assembly towards the ground. C. Shake the roller assembly up and down above the cardboard to pop the end cap and spring assembly free from the roller tube (Fig. 4B). The card board is to protect the end of the spring shaft when it breaks free. Fig. 2B Fig. 3B Fig. 4B 11
Special Instructions for Electric Drive Conversion Kit Step G: Install Roller End Cap Before installing the Roller End Cap, the Roller Tube may need to be cut to to fit into the housing properly. Cut tube an additional 7/8 (Fig. 5B). Step H: Dimple the Roller Tube Once Roller End Cap is in Roller Tube, Dimple the end of the Roller Tube into the grove of the Roller End Cap with a flat head screw driver in three places (Fig. 6B). Fig. 5B Fig. 6B Dimple 7/8" Roller End Cap Roller Tube Step I: Universal Super Shield Install motor as shown below (Fig. 7B). Fig. 7B Step J: Tarp Installation Slide Tarp into groove on Roller Tube and center (Fig. 8B). Fig. 8B NOTE: See Switch Kit for Wiring Instructions. 12
Housing Assembly for 111-0215 Universal Super Shield With Electric Drive ITEM PART # DESCRIPTION QTY 1 501-01XX SS Housing 9.5" x 80,84,87,89,93,96,100"lg. 1 2 501-13XX Roller Tube Assy 80,84,87,89,93,96,100"lg. 1 3 501-15XX Mounting Bar-Steel, 40,42,43.5,44.5,46.5,48,50"lg. 2 4 505-2502 1/4" Flat Washer USS 1 5 503-3108 5/16"-18 x 1 3/4"lg. HHCS Bolt 1 6 503-3105 5/16"-18 x 1"lg. HHCS Bolt 3 7 503-3101 5/16"-18 x 1/2"lg. HHCS Bolt 12 8 505-3102 5/16" Lock Washer 15 9 504-3103 5/16"-18 Nyloc Nut 1 10 506-9905 #10-32 x 1/2"lg. Phillips Head Pan 4 11 501-1235 Alum. Adaptor Plate - SW Motor 1 12 501-0632 System End Plate Stud Kit 1 13 501-1506 6" Large Steel Mounting Bracket 2 14 517-0906 12V DC Electric Motor 1 --- 514-0201 6 GA. Electric Wire (Not Shown) 100' --- 514-0505 Gray Quick Disconnect (Not Shown) 2 15 607-0061 Pulltarps Decal 1 REV: 11/08/07 BAB 10 14 11 8 6 13 5 15 4 1 8 9 17 2 7 16 3 19 17 13 12 12 18 20 Pullrod Hardware ITEM PART # DESCRIPTION QTY 16 501-0301 Tarp Return Ramps (Steel) 2 -- 501-0302 Tarp Return Ramps (Alum.) 2 17 501-0621 Rope Storage Kits (4 Steel Hooks) 1 -- 501-0608 Rope Storage Kits (4 Alum. Hooks) 1 18 517-10XX Pull Rope (20, 25, 30, 35, 40, 50') 1 19 Determined by Length Pullrod (85, 91, 93, 96, 100, 105" Lengths) 1 20 501-0612 Pullrod Hardware Kit 1 20 13
Housing Assembly 112-0215 Ultimate Aluminum with Electric Drive ITEM PART # DESCRIPTION QTY 6 1 501-01XX Ultimate Aluminum Housing - 80, 84, 87, 89, 93, 96"lg. 1 2 501-13XX Roller Tube - 80, 84, 87, 89, 93, 96"lg. 1 3 501-15XX Mounting Bar - 40, 42, 43.5, 44.5, 46.5, 48, 50" lg. (Specify Steel or Aluminum) 2 4 501-15XX 6" large Steel Mounting Bar (Specify Steel or Aluminum) 2 5 501-0229 Elec. Ultimate Aluminum End Plate - Left Side 1 6 501-0228 Ultimate Aluminum End Plate - Right Side 1 7 501-0803 System End Plate Stud Kit 1 8 517-0102 Flanged End Cap 1 9 501-9915 Roller Drive Aluminum End Cap 1 10 506-9916 Screw #8-18 x 3/4" Self Drilling 1 11 503-3105 5/16"-18 x 1"lg. HHCS Bolt 7 12 503-2502 1/4"-20 x 1/2"lg. SS BHCS 16 13 504-3103 5/16"-18 Nyloc Nut 1 14 503-3108 5/16"-18 x 1 3/4 Hex Bolt 1 15 505-2502 1/4" Flat Washer USS 7 16 505-3102 5/16" Lock Washer 15 17 503-3101 5/16"-18 x 1/2"lg. HHCS Bolt 8 18 607-0061 Pulltarps Decal 1 19 517-0906 12V DC Electric Motor 1 Pullrod Hardware REV: 09/19/16 WLH ITEM PART # DESCRIPTION QTY 20 501-0301 Tarp Return Ramps (Steel) 2 -- 501-0302 Tarp Return Ramps (Alum.) 2 21 501-0621 Rope Storage Kits (4 Steel Hooks) 1 -- 501-0608 Rope Storage Kits (4 Alum. Hooks) 1 22 517-10XX Pull Rope (20, 25, 30, 35, 40, 50') 1 23 Determined 4 by Length Pullrod (85, 91, 93, 96, 100, 105" Lengths) 1 24 501-0612 Pullrod Hardware Kit 1 19 5 15 4 11 14 12 9 3 18 17 16 16 13 21 2 1 12 24 10 20 21 11 16 15 8 23 22 7 24 14