R SIDE LOCKING TARP Installation Manual ROLTEC® SIDE LOCKING TARP MANUAL AND ELECTRIC TYPICAL OF FARM TRUCK, GRAIN CART, AND SEMI-TRAILER BOXES R BY: INSTALLER: These instructions must be given to the consumer. CONSUMER: Retain these instructions for further use. Save this manual for future reference. READ ALL INSTRUCTIONS CAREFULLY BEFORE INSTALLING OR USING THIS COVER. Actual parts may vary from those shown in this booklet. Tested. Trusted. Guaranteed. TABLE OF CONTENTS PREPARATION/TOOLS..........................................................................Pages 3-4 INSTALLATION INSTRUCTIONS........................................................... Pages 5-43 OPERATING/INSTRUCTIONS/SAFETY/INFORMATION..............Pages 34, 44, 50 PARTS AND DIAGRAMS.................................................................. Pages 46-49 INSPECTION AND MAINTENANCE..........................................................Page 51 FASTENERS AND HARDWARE ........................................................Pages 52-55 WARRANTY...........................................................................................Back Cover This owner’s manual applies to the ROLTEC® Hand Operated Tarp and the ROLTEC® 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 indicates steps that apply to the hand crank tarp. This symbol indicates steps that apply to the electric motor operated tarp. Both symbols indicate steps that apply to both the hand crank and electric operated tarp systems. ! NOTICE TO CONSUMER: This owner’s manual applies to the ROLTEC® Side Locking Tarp. Before using this product, read the operating instructions, maintenance and safety sections of this owner’s manual and save for future reference. NOTICE TO INSTALLER: It is recommended you take the time to read these instructions carefully before installing this cover even if already familiar with the product. Often improvements are made without prior notice. Always handle components with care to avoid personal injury or damage to components. 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 must be given to the customer. FOR YOUR RECORDS: DATE PURCHASED WHERE PURCHASED SERIAL NUMBER 2 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. Box must be square and straight. Center must not be pulled together or spread apart. Make adjustments prior to installation. Inspect box for sharp edges or points that make contact with tarp and/or cables. Remove or grind smooth. 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. 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 bolt. A 5/16” hole must be drilled to obtain correct tap drill hole size. Attach these bolts 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. Before you begin, measure the outer length and width of your box. Also measure the length of the tarp and the width of the end caps to ensure you have received the correct size. The tarp must measure between 8” and 16” shorter than the box length. The end caps must be at least 1/2” narrower than box width, usually 1/2” to 3” narrower. NOTE: Some systems may require end cap variations which will result in short outer tarp lengths. 3 PREPARATION (Continued) Tools & Equipment Most installations will require use of all these items Tools for Manual and Electric Install - Protective eyewear - Marking pencil - Step ladders or scaffolding - Lock pliers - Drill with 5/16” and 3/8” drill bits - Tape measure - Impact wrench with 9/16” socket - Two 1/2” wrenches, a 9/16” and 3/4” wrench - Hammer - Welder and helmet - C-clamps Additional tools for Electric Install - Drill with 3/16”, 7/32”, and 11/16” drill bits, #3 Phillips driver bit - 3/8” wrench - Heat gun - #25 Torx driver - Torque wrench (inch lbs.) - 1/8” Allen wrench - #1 Phillips head screw driver 4 INSTALLATION INSTRUCTIONS 1. END CAPS CAUTION: DO NOT STAND OR WALK ON END CAP A. FRONT END CAP Center side mount style end cap on front box. Hold firmly in place against box, drill 5/16” holes in box wall at each factory hole in end cap. Fasten with 3/8” x 1” self threading bolts. (See Figure 1A) Tilt end cap up 1/4” at center on ribbed side and use factory etch mark on caps as guide to drill 5/16” hole into top of box. Fasten with 3/8” x 1” self threading bolt. (See Figure 1B) Repeat at other end of cap. Maintain equal dim. on both sides Front end cap Cap must be shorter than box 1/2” min. 1-1/2” max. 3/8” x 1” self threading bolts at each hole in cap FIGURE 1A 3/8” x 1” self threading bolt Drill 5/16” hole at etched mark on cap Tilt end cap up 1/4” then mark and drill holes FIGURE 1B TIP: Sometimes it is necessary to modify end caps for proper fit by notching overhang, removing protruding objects from box, or by trim cutting end caps shorter if too wide for box. Both front and rear end cap should measure at least 1/2” narrower than top of box. 5 1. END CAPS (Continued) CAUTION: 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. B. REAR END CAP Center top mount style rear end cap on back of box. Position end cap to overhang back of box by 1/4”. Mark deepest location at each slotted hole on top of box at rear of end cap. After marks are made remove end cap, drill 5/16” holes at these locations. Turn 3/8” x 1” self threading bolts halfway in. Slide end cap slot under bolt heads. Ensure 1/4” overhang and finish tightening bolts. (See Figure 1C) Tilt end cap up 1/4” at center on ribbed side and use factory etch mark as guide to drill 5/16” hole into top of box. Fasten with 3/8” x 1” self threading bolt. (See Figure 1D) Repeat at other side of end cap. 1/4” Sealing rib in end cap (do not place a bow here) Tilt end cap up 1/4” at center All self threading bolts shown partially turned in to allow end cap slots to slide under bolt head, then finish tightening. FIGURE 1C 1/4” overhang at rear of box SIDE VIEW OF REAR END CAP 3/8” self threading bolt Drill 5/16” hole at etched mark on cap FIGURE 1D Drill 5/16” holes VIEW OF REAR END CAP 6 2. MOUNTING 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” in from front of box. The last bow should be placed 30” in from rear of box. Position remaining bows evenly spaced between first and last bow. (See Figure 2B on page 8 for bow placement) Attach bow pocket to inner sides of box, flush with top. Drill 5/16” hole at each location and use 3/8” x 1” self threading bolts. When possible secure bolts with flat washer, lock washer and nut. Bow extension Flat washer Nut Bow pocket Lock washer 3/8” x 1” self threading bolt Box Rail Drill 5/16” holes in box rail, turn self threading bolts into holes - insert bow & extension - then tighten bolts FIGURE 2A 7 2. MOUNTING BOWS AND RIDGE STRAP (continued) B. BOWS Start with first bow at front of box. Insert bow extension into bow. Place each end of bow into bow pocket. Center bow in an upright position. Adjust bow to set 1” higher than end cap. Drill 5/16” hole through end of bow and in extension. Drill hole so bolt head will not rub tarp. Turn 3/8” x 1” self threading bolt into bow assembly. IMPORTANT: Purpose of bolt is to hold bow rigid at properly set height. TIP: First, set front and rear bows to correct height. Install ridge strap on top of all bows and draw tight until no slack. Adjust remaining bows to just touch bottom of ridge strap. * 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 Standard one ridge strap in center Optional 2 ridge straps off center Last bow at rear First Bow From Front er b um n by ce ne a sp s o ing ft plu n i a le rem ows b ide of iv *D Warning: All bows must be used Clamp lock pliers 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 bolt. FIGURE 2B 8 2. MOUNTING BOWS AND RIDGE STRAP (continued) C. RIDGE STRAP Attach hook end of strap to hole in center of front end cap. If installing two ridge straps, attach straps to the off center holes. Run strap over bows. Attach ratchet end of strap to rear end cap. Draw strap tight. DO NOT OVER TIGHTEN. Trim cut extra strap to about 8”. Rear end TIP: Twisting the ridge cap strap prior to attaching it to ratchet will help deTwist ridge strap crease the chance of grain at ratchet end bouncing off of strap. The number of twists needed depends on the length of the trailer, adjust acFront cordingly. Make sure not end cap Trim cut to wind any twist in the excess ridge ratchet. strap Bow ALTERNATE RIDGE ROPE OPTION Attach hook end of rope to hole in center of front end cap. If installing two ridge ropes, attach hooks to the off center holes. Run rope over bows. Attach ratchet end of rope to rear end cap. Thread rope through ratchet as shown in Figure 2E, pull on loose end of rope to remove slack. Ratchet rope tight, need at least 4 wraps. DO NOT OVER TIGHTEN. Trim cut extra rope to about 8” and tie a knot to prevent fraying. Rear end cap Ratchet Front end cap Bow Pull rope through loop to remove slack, knot end to prevent fraying Loop rope through ratchet FIGURE 2E 9 3. LATCH PLATE A. POSITION LATCH PLATE Mount latch plate on 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 Figure 3A & 3B) 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. TIP: Use C-clamp to hold latch plate in proper position for drilling holes and bolting. Latch plate mounted continuously over length of box - flush at each end. Trim if necessary. FIGURE 3A 10 3. LATCH PLATE (continued) B. BOLTING LATCH PLATE Use small groove line on latch plate as center point to drill 5/16” holes and fasten with 3/8” x 1” self threading bolts. Place first bolt 1-1/2” in from ends and joints, second bolt 12” in from ends and joints and remaining bolts spaced 24” apart. Face of cap Round corner of box Starting edge of latch plate Drill 5/16” hole centered on groove (typical) Top of box Preferably 0” to 3” ” 24 ” /2 1-1 Typical of all remaining bolt locations ” 12 Start and stop latch plate flush at edge of box Typical for first bolt in from ends and joints Typical for second bolt in from ends and joints FIGURE 3B 11 4. TARP STOPS A. TARP STOP LOCATION These brackets secure the stationary side of the tarp to the box. For normal roll applications, mount brackets on PASSENGER side of box. For reverse roll applications, mount brackets on DRIVER side of box. Mark locations of first and last bracket preferably 8” in from each air dam. Divide remaining space by number of brackets left plus 1 to get equal spacing. Select appropriate tarp stop procedure shown on pages 17 and 18 and begin mounting tarp stops. 8” nu *Divi mb de er r of ema bra ini ck ng ets sp lef ace tp lus by on e 8” EXAMPLE: If - 2 quick release brackets are left, divide by 3 for 3 equal spaces. If - 3 quick release brackets are left, divide by 4 for 4 equal spaces. If - 4 quick release brackets are left, divide by 5 for 5 equal spaces. FIGURE 6 12 4. TARP STOPS (continued) B. Place first and last tarp stop brackets (wide tarp stops with set screws) preferably 10” in from air dam on outside of box so top of bracket is 1/4” down from top of box. For first and last tarp stop bracket, drill (4) 5/16” holes and use (4) 3/8” x 1” self threading bolts to mount brackets. For interior tarp stop brackets drill (2) 5/16” holes and use (2) 3/8” x 1” self threading bolts to mount interior brackets. C. Align lower hole in tarp stop with lower hole in bracket. Assemble with clevis pin and bow tie pin. Leave bracket in open position for now. D. For grain cart boxes, if using optional base bracket, see bolting procedure at bottom of page. 1/4” Tarp stop base bracket TIP: To remove bow tie pin, rotate it 1/4” turn, then pull it out from clevis pin. Clevis pins 1/4” Drill 5/16” holes and use (2) 3/8” x 1” self threading bolts for all interior brackets 8” air from da m Drill 5/16” holes and use (4) 3/8” x 1” self threading bolts for first and last bracket Bow tie pins VIEW AT TOP FRONT CORNER OF BOX (passenger side) OPTIONAL OFFSET BASE BRACKET Optional offset base bracket Grain cart box rail Use (2) or (4) 3/8” x 1” self threading bolts with lock washers and nuts. Tarp stop base bracket Drill 5/16” holes and use (2) 3/8” x 1” self threading bolts with lock washer and nut 13 4. TARP STOPS (continued) Drill 5/16” holes through tarp and box rail and use (2) 3/8” x 1” self threading bolts Tarp stop 8” 3” Optional offset base bracket Grain cart box rail Tarp stop OPTIONAL TARP STOPS E. At front, start first tarp stop 10” from air dam. With tarp centered on box, allow stationary tube to hang about 3” down from top of box rail. Position tarp stop over fixed tube, drill 5/16” holes through tarp and box rail and fasten with (2) 3/8” x 1” self threading bolts. OPTIONAL TARP STOP WITH OPTIONAL OFFSET BRACKET F. For grain cart boxes, if using optional offset base bracket, follow bolting procedure shown. Drill 5/16” hole. Use (2) 3/8” x 1” self threading bolts with lock use (2) 3/8” x 1” bolts with lock washers and nuts washer and nut Drill 5/16” holes through tarp and box rail and use (2) 3/8” x 1” self threading bolts Top mount tarp stop Top of box rail Stationary tube in tarp stop 14 OPTIONAL TOP MOUNT TARP STOP G. At front, start first tarp stop 10” from air dam. With tarp centered on box, position top mount tarp stop on top of box rail. Stationary tube should be in loop of tarp stops. Use holes on tarp stop as guide and drill 5/16” holes through tarp and box rail and use 3/8” x 1” self threading bolts to secure each tarp stop to box. 5. FIXED STATIONARY TUBE ASSEMBLY A. Spread tarp out on flat surface and pull tight lengthwise and across width. For boxes over 23 feet 6 inches, insert swaged end of fixed tube section into full end of second tube section. Align tube, weld, allow weld to cool, and grind smooth. B. Install end plug into full end of tube weldment. Insert tube, end plug first, into 4” pocket on tarp. 4” Pocket Fixed stationary tube Drive rivet End plug 4” pocket on tarp End plug Fixed tube Pull tarp tight across width Spread tarp out on flat surface and pull tight lengthwise 15 5. FIXED STATIONARY TUBE ASSEMBLY (continued) End plug on fixed tube Drive rivet C. Extend fixed tube 1/4” beyond edge of tarp. Drill 7/32” hole and set drive rivet. Drill 7/32” hole Tarp Drive rivet Drill 7/32” hole D. Pull tarp by hand to stretch tarp along fixed tube and pull out wrinkles, drill 7/32” hole and set second drive rivet. Tarp Swaged end of fixed tube Cut here 1/4” beyond tarp E. Cut fixed tube 1/4” beyond edge of tarp. Grind smooth. Tarp Discard left over portion F. Install another end plug. End plug Tarp 16 6. ROLL TUBE AND U-CLAMPS A. For boxes over 23 ft. 6 in, insert swaged end of roll tube into full end of other roll tube. Align tubes, weld, allow weld to cool, and grind smooth. Large 5” tarp pocket Splined shaft at rear of tarp B. For square back box trailers, roll tube length is total of box length plus distance to standoff minus 2 inches. Then cut roll tube at front, removing swaged end. Grind edges smooth. Slide roll tube into large tarp pocket with splined end to rear of tarp and box. For slant back boxes see step 5C on next page. Roll tube length Box length 90 Cut here Handle holder standoff Stationary tube in tarp 2” roll tube Full end of roll tube section Swaged end of roll tube section Splined shaft 17 6. ROLL TUBE AND U-CLAMPS (continued) Roll tube length Box length 90 Cut here Handle holder standoff Rear of box 1” 3-5” Front tarp strap 5” pocket on tarp C. For slant back box trailers, roll tube length is total of box length at top, plus distance of slant and standoff minus 2 inches. Then cut roll tube at front removing swaged end. Grind edges smooth. Slide roll tube into large tarp pocket with splined end to rear of tarp. D. Roll tarp up onto roll tube completely. Lift tarp onto box and center it. Secure tarp to box with tarp stops. See page 19. NOTE: If kit was ordered with ridge pole, assemble it to tarp prior to placing tarp onto box. E. Center first U-clamp on front tarp strap. Position screw on crease at bottom of tarp pocket. Fasten with screw. 1” U-clamp Self drilling screw Rear tarp strap Splined shaft U-clamp 18 F. Pull tarp snug along roll tube towards spline end. Install U-clamp on rear tarp strap. Then install U-clamp on remaining tarp straps. Driver may leave a sharp edge on head of screws, deburr if needed. 7. SETTING TARP ASSEMBLY ON BOX A. SETTING TARP ASSEMBLY Roll tarp assembly by hand to its open position, large tube to small tube. Have tarp stop clevis pins readily available for next sequence. Place rolled tarp up on top of side of box with tarp stop brackets. Center assembly from front to back of box. BE CAREFUL NOT TO LET TARP ROLL OFF BOX. Place small tube with tarp into brackets. Swing tarp stops up, align their holes with bracket holes and insert upper clevis pin. Repeat for all tall and short tarp stops. Insert all bow tie pins. This secures roll assembly to box. By hand, unroll tarp to the other side of box and let tarp hang down in the closed position. Check to make sure tarp is still centered from front to back of box and make adjustments as needed. Quick release tarp stop TIP: To remove bow tie pin, rotate it 1/4” turn, then pull it out from clevis pin. Bow tie pins Stationary tube shown locked in the quick release bracket with clevis pin Quick release base bracket 19 8A. BUNJI STRETCH CORD RETURN Choose appropriate step 8 instructions based on your return system. Bunji stretch cord roll return use pages 20-21, spring roll return use pages 22-23 procedure or synthetic cable box returns use pages 24-25. A. BUNJI STRETCH CORD ROLL RETURN Bunji stretch cord return is pre-assembled and folded in half when shipped. Unfold assembly, align open ends and connect tubes together. NOTE: For electric tarp kits, install this roll return in rear of tube, opposite end of tarp motor. Corner guide PVC tubes joined together End plug Protective cord cover 20 8A. BUNJI STRETCH CORD RETURN (continued) NOTE: Before installing, hold corner 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. B. Insert return assembly into roll tube and tap in place. Insert return assembly into roll tube and tap in place End plug C. Fasten plug with #8 x 1/2” Phillips head self drilling screw. End plug #8 x 1/2” Phillips head self drilling screw 1/2” Bunji guide D. Place corner guide 1/2” back from end cap/latch plate. Mark and drill two 5/16” holes. Fasten guide with two 3/8” x 1” self threading bolts. 3/8” x 1” self threading bolts (2x) Path of cord E. Cord path should go up and over end cap. Inspect path for sharp edges and remove if needed. Cord cover 21 8B. SPRING RETURN A. SPRING RETURN Spring return is pre-assembled and folded in half when shipped. Unfold assembly and apply adhesive (supplied in kit) on all sides of male end of PVC connection. Slide PVC tubes together, tape joint, and let glue set, dry time will vary on environment. Handle this joint with care. NOTE: For electric tarp kits, install this roll return in rear of tube, opposite end of tarp motor. PVC tubes End plug e tu Slid Corner guide PVC connections, apply adhesive here, all sides Synthetic cable 22 her get to bes 8B. SPRING RETURN (continued) NOTE: Before installing, hold corner guide at location and inspect path of cord. 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. B. Insert return assembly into roll tube and tap in place. Insert return assembly into roll tube and tap in place End plug C. Fasten plug with #8 x 1/2” Phillips head self drilling screw. End plug #8 x 1/2” Phillips head self drill screw 1/2” Corner guide D. Place corner guide 1/2” back from end cap/latch plate. Mark and drill two 5/16” holes. Fasten guide with two 3/8” x 1” self threading bolts. 3/8” x 1” self threading bolts (2x) Path of cord E. Cord path should go up and over end cap. Inspect path for sharp edges and remove if needed. 23 8C. FRONT AND REAR CABLE RETURN A. Align bottom edge of cable return with top edge of box behind cap. Slide cable return to roll tube side until tab meets bottom of hem. (See Figure 8A) Ensure synthetic cable runs unobstructed along entire path of travel. B. Mark and drill 5/16” holes at mounting tab at each end. Secure cable return with 3/8” x 1” self threading bolts, lock washers and nuts. C. Place center mounting bracket (tab up) at center of cable return box. Mark and drill 5/16” hole and attach using 3/8” x 1” self threading bolt, lock washer and nut. D. Slide cable return loop over roll tube. Next slide cable retainer and retaining collar on roll tube. Secure collar with #8 x 1/2” Phillips head self drilling screw. Now slide vinyl cap over end of roll tube (See Figure 8B) End cap Turn 3/8” x 1” self threading bolt through bracket and 5/16” hole with lock washer & nut Align bottom edge of cable return with top of box behind cap Top of box behind cap Butt tab up to bottom of hem Turn 3/8” x 1” self threading bolt through 5/16” hole secure with lock washer & nut (both sides) FIGURE 8A 24 8C. FRONT AND REAR CABLE RETURN (continued) Cable retainer Roll tube extension Retaining collar #8 X 1/2” Phillips head self drilling screw Vinyl cap FIGURE 8B Front Cable Return Option (Non-Square) NOTE: For square cap use mounting location similar to Figure 8A Front cable return option (See Figure 8C for mounting location) Make sure roll tube extends 4” beyond edge of box. Slide cable return loop, cable retainer, retaining collar, and new vinyl cap onto roll tube. Secure retaining collar with #8 x 1/2” Phillips head self drilling screw. (See Figure 8B) Existing non-square end caps Turn 3/8” x 1” self threading bolt through bracket (tab down) and 5/16” hole with lock washer & nut Mount cable return as close to edge of box as possible, mounting tab may be bent around corner Turn 3/8” x 1” self threading bolt through 5/16” hole with lock washer & nut (both sides) FIGURE 8C 25 9. REAR BUNJI RETURN KIT NOTE: This bunji kit is OPTIONAL on manual tarps. If ordered, install it at rear of box. A. EXTRA BUNJI RETURN KIT Start with bunji guide on cord end next to collar. Place it on latch plate at rear of box for manual system as shown, or at front of box for electric system. Adjust it to extend 5/16” to 3/4” beyond face of end cap. Make sure cord path will clear bolt heads on face of end cap. (See Figure 9A and 9B) Hold bunji guide in correct position and mark hole locations. Drill two 5/16” holes. Mount bunji guide with 3/8” x 1” self threading bolts. Bunji cord Allow for clearance between bolt heads and bunji cord Bunji guide 5/16” to 3/4” FIGURE 9A 5/16” to 3/4” Bunji guide Collar 3/8” x 1” self threading bolts FIGURE 9B 26 9. REAR BUNJI RETURN KIT (continued) B. Take bunji guide on opposite end, hold it up on latch plate and pull until slack is out of cord. Then stretch it another 12 inches and mount bunji guide at this location. Drill two 5/16” holes and fastening with 3/8” X 1” self threading bolts. P ko ac sl ull ord fc o ut 2” +1 Bunji guide 3/8” x 1” self threading bolts (2x) Mount bunji guide here 27 10. CRANK HANDLE ASSEMBLY NOTE: For electric tarp installs, skip steps 10 through 14. Continue with step 15. A. U-JOINT AND 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 degrees to handle. Use rubber hammer to 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 tight fit. A coating of grease will ease this process. B. CRANK HANDLE AND HANDLE EXTENSION Insert crank handle into handle extension selecting 1 of 4 holes according to desired length and align holes to bolt together using 3/8” x 1-3/4” bolt and nut. 3/8” x 1-3/4” bolt Handle extension Nut Crank handle Handle extension Spring pin Sleeve end of U-joint C. ATTACH HANDLE TO SPLINE With tarp and roll tube hanging loose below latch plate, slide U-joint onto splines so that the handle hangs straight down parallel with box wall. Insert wire lock pin to secure U-joint to roll tube. 28 Apply coat of grease here around tube 10. CRANK HANDLE ASSEMBLY (continued) D. ADJUSTING HANDLE LENGTH 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 re-bolt. (See below) 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 Approx. 18” Roll tube Handle must be 90o on slant back boxes Bunji collar Roll tube VIEW IF ON A SLANT BOX 29 11. MOUNTING PINLESS HANDLE HOLDER NOTE: For Grain Carts, refer to single sheet instruction on mounting handle holder extension. A. HANDLE HOLDER Using crank, turn roll tube up (counter clockwise) until it is firmly secured under latch plate. Bring crank arm down toward box to full vertical position. Hold crank arm firmly with both hands and lift it toward center of box, until you find location you want to mount crank holder bracket. The pinless handle holder should be located above handle portion of crank. Mark and drill two 5/16” holes and secure holder bracket with 3/8” x 1” self threading bolts. Attach pinless crank holder to bracket with 1/2” x 1” bolt. Crank handle and mount Safety/ operating decal Pinless crank holder Holder bracket 3/8” X 1” self threading bolt Crank handle in holder 30 Spacer 1/2” X 1” bolt 12. ATTACH SAFETY / OPERATING DECAL A. OPERATING DECAL With crank handle placed in holder to secure it, locate the spot for the safety/ 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. IMPORTANT: Peel warning stickers from sheet and attach to visible area near unloading controls inside cab and on box or trailer. STOP WARNING STICKER 31 13. TARP TENSION ADJUSTMENT A. 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 Figure 13A below. Make correction if needed. Next, make sure that wire lock pin is in correct position to encompass around spline shaft as shown in Figure 13B below. Make correction if needed. INCORRECT CORRECT FIGURE 13A CORRECT INCORRECT FIGURE 13B 32 14. TARP TENSION ADJUSTMENT (continued) B. 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 to place it in the handle holder. (See chart for normal tension settings for other handle lengths and add about 5 lb. extra at initial tarp installation.) C. SET TENSION Remove U-joint from spline shaft, rotate one to two teeth and reattach onto shaft. 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. D. 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. Recommended Tarp Tension: Handle Lgth. = lbs, of Lift 8 ft. Long = 25 lbs. 10 ft. Long = 20 lbs. 12 ft. Long = 15 lbs. REPLACEMENT DECALS ARE AVAILABLE THROUGH AGRI-COVER®, INC, OR AGRI-COVER DEALERS. 33 MANUAL CRANK OPERATING INSTRUCTIONS CLOSING FROM OPEN POSITION 1. Crank the tarp up under the latch plate. 2. Bring the crank arm down to a vertical position. 3. Lift the crank arm up to the crank retainer. Crank retainer Crank arm Latch plate See chart lbs. of lift Down Lift To adjust the tarp tension: 1. Allow the tarp to roll down away from the latch plate. 2. Remove the crank arm from the splined shaft. 3. Rotate the crank one or two teeth and reassemble. Recommended Tarp Tension: Handle Lgth. = lbs, of Lift 8 ft. Long = 25 lbs. 10 ft. Long = 20 lbs. 12 ft. Long = 15 lbs. 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. IMPORTANT: 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. 34 15. UPPER PIVOT ARM AND MOTOR (Continue here for electric operated tarps) A. Assemble motor to bracket on upper pivot arm. Use three 5/16” x 3/4” bolts with lock washers. Attach motor cover with hex flange screws and nylon spacers. Then locate lower pivot arm mounting bracket and lower pivot arm and proceed to next step. 5/16” x 3/4” bolts (3x) Nylon spacer Lock washer Hex flange screw Upper pivot arm Electric motor Motor cover 35 16. UPPER PIVOT ARM AND PIVOT POINT A. PIVOT ARM BRACKET LOCATION For lower pivot arm, locate pivot arm bracket on outside of box 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 bolts. 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 Figure 16A) Tap plug into end of lower pivot arm. 36” 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 10”. 3/8” x 1” self threading bolts Pivot arm bracket Cable ties Lower Upper pivot pivot arm arm 1/2 of bo x width 1/2” x 1” bolt FIGURE 16A 36 17. MOTOR ADAPTER AND ALIGNMENT A. MOTOR ADAPTER At front of roll tube, apply thin layer of grease to motor adaptor then slide adapter onto tube. Slide return loop over motor adapter. (See Figure 17A) Do not drill or bolt to roll tube yet. B. MOTOR TO ROLL TUBE Position upper pivot arm with motor over top of lower pivot arm. Hold onto motor and slide drive shaft with thin layer of grease into motor adapter on roll tube. Turn adapter by hand until its hole aligns with hole in motor shaft. Insert 3/8” x 1-3/4” 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: Cord should NOT ride on top of cap - it should travel in front of cap as roll tube opens. Photos show a properly aligned system. Now drill hole in roll tube and use 3/8” x 2-3/4” bolt to secure motor adapter. Top of box When fully assembled, cord should have sufficient tension to almost lift tarp tube. If needed, adjust cord tension by tying new knot at far end of cord TIP: Periodically grease drive shaft and motor adapter 3/8” x 2-3/4” bolt Motor adapter 3/8” x 1-3/4” bolt with lock nut Roll tube Cord collar Motor shaft 90o Cord Cord collar FIGURE 17A 37 18. ELECTRIC MOUNTING INSTRUCTIONS TIP: Dielectric silicone is provided for electric wire connections. Use as needed. 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.) 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 48) For semis use dual pole connector at front of trailer. (See page 39 for details) FIGURE 18A 6 ga. double strand wire (from solenoid to tarp motor) 14 ga. wire from switch to solenoid Solenoid Caution/operating decal HD dual pole connector Rocker switch inside cab Circuit breaker 40 amp 6 ga. double strand wire (from solenoid to tarp motor) Place only the lower portion of this decal in a location visible to the operator or all warranties are void! IMPORTANT: Peel warning stickers from sheet and attach to visible area near unloading controls inside cab and on box or trailer. 38 Caution/Operating Decal 18. ELECTRIC MOUNTING INSTRUCTIONS (continued) 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 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. Loosen set screws slide bare wire into tubes – turn both set screws tight into each bare wire Thread cutting bolt 2x, if unable to use nut behind frame drill 1/4” hole and turn thread cutting bolt into frame Lock washer Dual pole Flat washer Nut socket Bolts for ring terminals Dual pole plug Strip wire insulation off as needed Red (+) wire to (+) battery terminal Insert wire retainer clip in plug as shown Use set screw to anchor wire to plug receptacle Heat shrink tube Red wire to terminal 2 on motor Phillips head screw at end plug 39 18. ELECTRIC MOUNTING INSTRUCTIONS (continued) NOTE: If installing the optional Command Station or COMMAND-10® Wireless Remote, skip step 18B through 18H. Use instructions that come with those kits. B. SWITCH LOCATION AND INSTALLATION Select convenient location in cab to mount switch bracket with two #14 x 1” self drilling Phillips screws through slots in back of bracket. (See Figures 18A & 18B) Route 14 ga. wire from switch to location of solenoid near 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. (See Figure 18B) Push switch into mount bracket until it snaps (locks) onto bracket. C. CAUTION/OPERATING AND STOP WARNING STICKERS Locate a suitable location at front driver side of box. Clean surface and apply caution sticker. (See Figure 18A) Locate visible area near unloading controls inside cab and on box. Clean surface and apply STOP warning stickers. D. SOLENOID Mount solenoid in protected area near battery using (2) #2 x 1” self drilling Phillips screws. For reference, see schematic on page 48. 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 Black to open ” 5/8 Green to center Typical for all heavy gauge wire eyelets White to close Front of bracket Typical heat shrink tube for all heavy gauge wire connections #14 x 1” Phillips head self drilling screw FIGURE 18B 40 Rubber terminal boots for solenoid and motor connections only FIGURE 18C 18. ELECTRIC MOUNTING INSTRUCTIONS (continued) E. 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. Prepare end of light gauge green wire from switch with 1/4” ring terminal. F. HEAVY GAUGE WIRES Split heavy gauge wire at solenoid about 4” back. Prep ends of black and red heavy gauge wires leading from motor and battery with heavy gauge 1/4” ring terminals, heat shrink tubes and rubber boots for (4) solenoid studs. (See Figure 18C) Attach wires to studs on solenoid. Note the light gauge jump wire leads through same rubber boot with black (-) wire from battery. The green light gauge jump wire leads through same rubber boot with red (+) wire from battery. When attaching ring terminals always hold base nut while tightening top nut. Do not over tighten. Connect white light gauge wire to left terminal and black wire to right terminal (See wiring schematic on page 48). G. CIRCUIT BREAKER Install circuit breaker in line on red (+) wire close to battery using 5/16” ring terminals and heat shrink. (Prep wires as shown on page 40) H. BATTERY Prepare end of heavy gauge black wire for battery (-) post with heat shrink tube and 3/8” ring terminal. Prep end of heavy gauge red wire for battery (+) post with heat shrink tube and 1/2” ring terminal. Do not connect wires to battery now. 5/16” terminal at motor 1/2” terminal Heat shrink tube (typical) Circuit breaker 3/8” terminal Red 1/4” terminal Black Green Black Black Jump wire INSTALLATION TIP: Wire Schematic Page 48. #2 self drilling Phillips head screw White FIGURE 18D 41 19. MOTOR CONNECTIONS A. WIRING MOTOR Prepare wire ends for motor terminals with rubber terminal boots, 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. Torque to 42 LB-IN. At battery, first attach RED wire to (+) post. Then attach BLACK wire to (-) post. Check power by activating switch to open position. If motor turns tarp in wrong direction, reverse black and white 14 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 Flat washer Red wire Flange nut, torque to 42 LB-IN NOTE: Image shown without terminal boots and motor cover off. 42 20. TARP TUBE FASTENERS Check to make sure stationary tube is centered on box. At front and rear wide tarp stops, tighten set screws with Allen wrench. IMPORTANT: These set screws prevent tube and tarp system from sliding back when raising box or from road vibration. Wide tarp stop at front and rear of tarp 1” Stationary tube Tighten set screw with Allen wrench ROLL TUBE DEFLECTOR #14 x 1” Phillips head self drilling screw Roll tube deflector Roll tube deflectors fasten to side of box to keep roll tube from damaging paint on sides of trailer. Fasten with #14 x 1” Phillips head self drilling screw. Use caution do not over torque screw, this may damage deflector. #14 x 1” Phillips head self drilling screw 43 ELECTRIC MOTOR OPERATING INSTRUCTIONS NOTE: For kits with Command Station or the COMMAND-10® Remote Control refer to those manuals for 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. Fully closed is when tarp roll tube is tight up under latch plate. 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. 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. IMPORTANT: 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. 44 SERIAL NUMBER LOCATION TO ORDER A REPLACEMENT TARP FIND YOUR TARPS SERIAL NUMBER WHERE SHOWN. Serial number is printed at the rear of the tarp on the stationary tube side. 45 24 5 46 22 19 25 23 3 2 12 11 1 9 26 21 4 20 26 13 10 17 16 6 15 14 18 25 8 7 26 29 28 27 ROLTEC SIDE LOCKING TARP PARTS DIAGRAM ROLTEC SIDE LOCKING TARP PARTS LIST Item Description 1 Bunji cord 2 Bunji return end plug, 2” (internal) 3 Bunji return cord cover 4 Front end cap (side mount shown) 5 Latch plate (aluminum) 6 Standard tarp stop ASM (quick release) 7 Crank handle stand-off (7” shown) 8 Pinless crank handle retainer 9 2” steel roll tube 10 Stationary tube 11 Bunji return tube, swaged end 12 Bunji return tube, open end 13 U-joint 14 Crank handle 15 Handle extension 16 Roll pin 17 Wire lock pin 18 Stationary tube end plug 19 Bow 20 Bow extension 21 Bow pocket 22 Ridge strap 23 Bunji guide 24 U-clamp & screw 25 Drive rivet 26 3/8” x 1” self threading bolt 27 Spacer 28 1/2” x 1” bolt, serrated flange 29 Wide tarp stop ASM (quick release) 47 WIRE SCHEMATIC DIAGRAM WIRE SCHEMATIC DIAGRAM RED HEAVY GAUGE BLACK HEAVY GAUGE SOLENOID RED HEAVY GAUGE GREEN 14 GA WHITE 14 GA BLACK 14 GA JUMPER WIRE MOTOR CLOSE OPEN ROCKER SWITCH (IN CAB) BLACK HEAVY GAUGE BATTERY 48 40 AMP BREAKER ELECTRIC PARTS Qty. Part# Description 2 10914 Phillips Self Drilling Screw #14 x 1 2 30312 Eyelet Terminal Ring 6 ga. x 5/16” 4 40627 Hex Nut Serrated Fig/ 5/16” - 24 1 40649 Rocker Switch 12v 10 Lin. Ft. 40653 Wire, 3 Conductor, 14 ga. 1 40664 7/16” ID Rubber Grommet 1 40673 Switch Mounting Bracket 1 20047 Socket, Dual Pole Connector 1 20048 Plug, Dual Pole Connector 1 40991 Lower Pivot Arm 1 10774 Upper Pivot Arm 1 10739 Circuit Breaker, 40 Amp 2 80006 Washer, Flat #10 1 10739 Circuit Breaker 40 Amp 1 70498 Solenoid GRP (includes jump wire) 1 70491 Wire ASM, Jumper 1 30314 Terminal Ring 1/2” 6 ga. 1 30313 Terminal Ring 3/8” 6 ga. 2 30647 Terminal Ring #10 6 ga. 1 50948 Electric Motor 1 30723 Mount Bracket Pivot Arm 1 40956 1/2 x 1” Pivot Bolt 2 10178 Self Lock Nuts 1 40964 Electric Motor Adapter 1 30454 O-Ring/Bunji Collar 2 60779 Bunji Corner Guide 1 10905 3/8 x 2-3/4” Bolt 1 10902 3/8” Lock Nut 1 10268 Bunji Cord 20046 6 ga. Double Strand Cable (Spec. Lgth.) 1 30649 Heat Shrink Kit 1 50390 Electric Operating Decal 1 30648 Breaker Cover 4 50996 Terminal, Ring 1/4” 6 GA Non-Insulated 4 70278 Cover, Terminal, 8-2 GA Rubber Boot 2 70298 Screw, PH Pan head #2 Self Drilling, 10-16 x 1 Zinc PL 5 70428 Terminal, 1/4” 14 GA Push on Female Insulated 1 70446 Terminal, Ring 1/4” 14 GA Insulated 49 SAFETY INFORMATION ! SAFETY INFORMATION • Always use adequate caution when operating tarp. • Make sure tarp is open before unloading or loading. • Make sure nobody is on or near tarping system before and during operation. • Do not operate tarp with box hoisted in an elevated position. • If tarp is covered with snow, its removal is important before operating. • End caps must be free from grain that may be piled on them. Grain should not be heaped higher than end caps. • Do not operate this vehicle at highway speeds, while tarp system is in the “open” position. • Instruct everyone who will operate this tarp the proper procedures, or have them read this entire manual. • Avoid direct pressure washer spray to electric motor and motor connections. 50 INSPECTION MAINTENANCE ! INSPECTION / MAINTENANCE • Periodic preventive maintenance should be practiced. Inspect tarp and hardware for abrasions or loosened bolts that may need adjustment and/or repair and adjust tension when needed. Tarp must be kept to a recommended tension setting equally on both ends, or excessive tarp wear may occur. • 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. • Always use genuine Agri-Cover, Inc. replacement parts if repairs are needed. • Bunji cord recoil memory will typically take longer if left open for a long period of time or when operated in cold weather. • Periodically remove handle and apply grease to splines. • Routinely grease zerk fitting on crank handle U-joint. • Check the tightness of mounting bolts and electrical connections, remove any dirt or corrosion that may have accumulated on the electrical connections. • Do not attempt to disassemble the motor or gearbox. Disassembly will void warranty. SAVE THIS MANUAL FOR FUTURE REFERENCE 51 Agri-Cover Fasteners and Hardware Parts are not actual size. Each part may not be included in every kit. All are subject to change without notice. Bolts 52 Bolts 53 Washers Nuts 54 Terminal Rings Pins 55 MANUFACTURER’S LIMITED WARRANTY Agri-Cover, Inc. extends the following limited warranty on its ROLTEC® Side Locking Tarp to the original retail purchaser: Agri-Cover, Inc. warrants its ROLTEC® Side Locking Tarp 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. ANY IMPLIED WARRANTY APPLICABLE TO THE ROLTEC® SIDE LOCKING TARP 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. R SIDE LOCKING TARP 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. For ACI patent information, please visit: http://www.agricover.com/patents/ PHONE 800-233-4655 8:00 am - 5:00 pm CST Monday through Friday except Holidays 56 PN 60856_N Product subject to change without notice © 2016 AGRI-COVER, INC. ALL RIGHTS RESERVED. 072816