TARP KIT INSTRUCTIONS

082608   Part No. 50118 REV:A.          © COPYRIGHT 2006 AGRI-COVER, INC., ALL RIGHTS RESERVED
                        8:00 a.m. - 5:00 p.m., Central Time – Monday through Friday, except holidays.
                                P.O. Box 508 • Jamestown, ND 58402-0508 • 701-251-1427




                                                                                      TARP KIT
                                                                                   INSTRUCTIONS
                                                                        For use when installing electric motor option on
                                                                         EZ-LOC (latchplate style) systems and when
                                                                        converting existing hand crank tarps to electric.

                                                                                          CONSUMER:
                                                                              Retain these instructions for future use.

                                                                                  READ ALL INSTRUCTIONS
                                                                         CAREFULLY BEFORE INSTALLING OR USING THIS
                                                                                    ELECTRIC MOTOR KIT
NOTE: Due to the many variations of box                      MOUNT BUNJI STRAP TO
shapes - the install and parts may vary                      LATCH PLATE AS SHOWN.
                                                             DRILL 5/16 HOLE AND USE
from these instructions.                                     3/8X1 SELF THREAD HEX
                                                             HEAD BOLT
START HERE: When converting exist-                                            LEAD BUNJI CORD THROUGH
ing tarp from hand to electric.                                               GROMMET HOLE AND TIE KNOT
                                                                              TO PREVENT CORD FROM
                                                             MOUNT THE        PULLING THROUGH HOLE
STEP 1:                                                      CORNER
Roll tarp up to open position. Unhook crank                  BUNJI GUIDE
                                                             BRACKET AS
handle. Remove tarp and tube from box.                       SHOWN

STEP 2:
Remove roll tube from tarp, turn it end for end
so splined end protrudes through front of tarp                                                               -0”
                                                                                                          10’
and existing roll return hardware and bunji cord
can be used at rear of box.
Reattach roll tube to tarp.

STEP 3:
Reattach tarp and tubes to box. Leave tarp in                                    3/8 x 1 FLAT HEAD COUNTER SUNK ALLEN
rolled open position for now. On latch plate                                     HEAD BOLT - DRILL 5/16 HOLE - TURN 3/8X1
side of box front, relocate bunji eye bolt to                                    SELF THREAD BOLT INTO HOLE TO CUT
                                                                                 THREADS - THEN BACK OUT AND USE ALLEN
rear.                                                                            HEAD BOLT FOR FINAL ASSEMBLY.

START HERE: When installing all new
tarp system.                                                                         FIGURE 1
STEP 4:
Install new front bunji cord system at front. Figure 1. Then unroll tarp to closed position.



                             PARTS LIST                                                      PARTS LIST
        Qty.        Part #   Description                                  Qty.      Part #   Description
          4         10914    Phillips Self Drilling Screw #14 x 1          1        10739    Circuit Breaker, 40 Amp
          4         30312    Eyelet Terminal Ring 6 ga. x 5/16             1        10867    Nylon Cable Ties (Kit)
          1         40618    Solenoid 12V Motor Reversing                  1        10795    Electric Motor
          4         40627    Hex Nut Serrated Flg. 5/16-24                 1        30723    Mount Bracket Pivot Arm
          1         40649    Rocker Switch 12v                             1        40956    1/2”x1” Pivot Bolt
      10 Lin. Ft.   40653    Wire, 3 Conducter, 14 ga.                     2        10178    Self Lock Nuts
          4         40656    Terminal Boots, Lug Type 8-2 ga.              1        40964    Electric Motor Adapter
          5         40661    Female Push On Terminal 14 ga. 1/4            1        30454    O-Ring Collar
          1         40664    7/16” ID Rubber Grommet                       1        30460    Bunji Corner Guide
          1         40670    Eyelet Terminal Ring 14 ga. 5/16              1        10293    Bunji Strap
          1         40673    Switch Mounting Bracket                       1        10905    3/8”x2-3/4” Bolt
          1         20047    Socket, Dual Pole Connector                   1        10902    3/8” Lock Nut
          1         20048    Plug, Dual Pole Connector                     1        10268    Bunji Cord
          1         40991    Lower Pivot Arm                                        20046    6 ga. Cable (Specify Length)
          1         10774    Upper Pivot Arm                               1        30649    Heat Shrink Kit




                                                                    -5-
BLACK                                                                      RED

                        GREEN
                                                                                                  BLACK
                        WHITE




                                                                                    RED




                                                                   BLACK      RED




                                           WIRE SCHEMATIC DIAGRAM



STEP 5:
At front, slide O-ring collar onto motor spline adapter and slide assembly over splines and on tube. Use hole in assembly
as guide to drill new hole into roll tube and bolt tight with bolt and nut. Attach bunji cord to O-ring collar with permanent
knot. There should be tension on cord when tied. Trim end of bunji cord and wrap with tape to prevent strand fraying. See
Figure 2. At rear of tube, reinstall existing bunji cord and roll return hardware to roll tube and latch plate.

                                     TOP OF BOX




                                ELECTRIC
                                MOTOR
                                ADAPTER                                             STRETCH BUNJI
          3/8”x2-3/4”
          BOLT WITH                                                                 CORD AND TIE
          LOCK NUT                                                                  PERMANENTLY
                                                                                    TO O-RING
                                                                                    COLLAR



                                                                     GRIND OFF METAL
                                                                     BURR IF NEEDED
                                                                     TO ALLOW ADAPTER
                                                                     TO SLIDE ON
                                                                     SMOOTHLY (ONLY
                                                                     ON CONVERSION
                                                                     INSTALLS)

                          O-RING
                          COLLAR                        FIGURE 2
                                                             -1-
STEP 6: MOTOR AND PIVOT ARMS

A. MOUNTING LOWER PIVOT ARM
Locate the pivot point on the outside of the box for the lower pivot arm about 36” from the bottom of the end
cap at the center of the box. Drill a 5/16” hole through the box wall and mount the pivot arm bracket to box
wall. Insert pivot bolt into pivot arm bracket and bolt tight. Then turn a lock nut onto pivot bolt allowing enough
bolt thread to support lower pivot arm and a second lock nut. Attach lower pivot arm on and turn the second
lock nut in place allowing pivot arm freedom to pivot.

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 INCHES.

B. MOUNTING THE MOTOR
Next take the motor and slide the upper pivot arm over the top of the lower pivot arm and while holding the
motor align the motor shaft to the motor shaft extension in the roll tube. Then by hand turn roll tube until the
hole aligns with the hole on the motor shaft and bolt tight with bolt and lock nut. The pivot arms must slide
freely and the entire motor assembly must be clear of any obstructions to operate when opening or closing. If
the lower pivot arm extends past the top of the motor in the closed position, the excess can be cut off.




E. MOTOR CONNECTIONS
                                                                        HEAT SHRINK
Remove the screws holding the motor cover and                           TUBE
remove cover. Strip and prep wire ends for con-
nectors to motor. Refer back to Figure 6 (page
3). Slide a piece of heat shrink tube over the ends
                                                                                      1
of the wires and attach 5/16 eyelets to the ends.                                         2
Slide heat shrink tubes over end and heat to seal.
Attach BLACK wire to terminal 1 on motor. Attach                                              FLAT WASHER
RED wire to terminal 2 on motor. Check the motor                                                            MOTOR COVER
direction by attaching black wire to solenoid (see                     RED WIRE           FLANGE NUT
Figure 8) and activate the switch to the open posi-
tion. Does the motor turn the tarp open? If yes,
attach motor cover. If the motor turns the wrong
direction, change wire leads on the motor to oppo-                                            FIGURE 9
site connections. This will make the motor turn the
opposite direction. Attach the motor cover.

                   ELECTRIC MOTOR OPERATING INSTRUCTIONS
STEP 1: CLOSING FROM OPEN POSITION
Turn switch to the CLOSED position and hold. Visually view tarp position and release switch when tarp is fully closed.
STEP 2: OPENING FROM CLOSED POSITION
Turn switch to the OPEN position and hold. Visually view tarp position and release switch when tarp is fully open.
NOTE: Holding switch when roll tube has reached the end of cycle and is no longer turning will trip the automatic cir-
cuit breaker. After breaker resets, switch will activate motor again. To reduce unnecessary strain on tarp components,
release switch when rolling tarp reaches fully open or fully closed position.
                                                            -4-
BLACK WIRE TO
STEP 8: CONTINUED                                                                   TIGHTEN TOP NUTS         MOTOR FORWARD
                                                                                    TO 35 INCH LBS.          ON SOLENOID
D. SOLENOID
Mount solenoid in protected area near battery using self drilling
screws. Split 6 ga. wire at solenoid about 4” back. Slip rubber ter-
minal boots and heat shrink tubes on wire. Then strip wire about
                                                                             DO NOT
5/8” back and attach 5/16” connectors. Apply heat to shrink tubes.           REMOVE
Refer back to Figure 4 if needed.                                            BASE
                                                                             NUTS
Attach RED wire to motor reverse on solenoid. Attach all BLACK
wire to motor forward on solenoid. Tighten nuts - use caution not
to over tighten. See Figure 7.                                                                           RED WIRE (FROM TARP
                                                                                                         MOTOR T2) TO MOTOR
                                                                                                         REVERSE ON SOLENOID
At solenoid - strip WHITE 14 ga. wire 3/8” back, slide push-on
connector on and crimp tight. Repeat procedure on BLACK wire.                                 FIGURE 7
See Figure 8. Push WHITE wire onto T1 at solenoid. Push                                                              RED TO
                                                                                                       RED RUBBER
BLACK wire onto T2. See Figure 8. Push RED wire (that will                                             BREAKER COVER BATTERY
                                                                                              BATT+
attach to BATT+ at solenoid) and GREEN wire through same rub-
ber boot. Strip GREEN wire, attach 14 ga. eyelet and crimp. Strip                          AUX
RED wire, attach 5/16” eyelet and crimp. Attach both wires to
BATT+ on solenoid. See Figure 8.
At circuit breaker - cut and strip RED 6 ga. wire ends. Slide heat
shrink tube over wire. Attach (#10) 5/16 eyelet and heat to shrink
                                                                                                                   BLACK
heat seal tube. See Figure 4 for reference. Slip end of RED wire                                        BREAKER    WIRE TO
from battery through rubber breaker cover and attach to BATT+ end                                       40 AMP     BATT-
of breaker. Attach AUX end of breaker to RED wire from BATT+ on
solenoid. See Figure 8. Strip BLACK wire from battery negative for
eyelet. Slide on rubber boot, heat shrink tube and attach 5/16 eye-                                        BLACK
let. Do not connect BLACK wire to (BATT-) solenoid now. See                                                T-2
Figure 8.                                                                             GREEN
                                                                        WHITE T-1     BATT+               FIGURE 8
INSTALLATION TIP: See Wire Schematic page 5.



 STEP 7: WIRING MOTOR
                                              MOUNT PIVOT ART
A. ROUTING WIRE                               BRACKET TO
                                              CENTER OF BOX

From the front of the box bring
the wire up to the pivot bolt and
loop it around leaving slack for
movement. Next bring the wire
along the lower pivot arm up to                                                                                      NYLON
the top pivot arm to the motor                                                                                       CABLE
                                                                                                                     TIES TO
connectors. Use nylon cable ties                                                                                     SECURE
to hold wire in place on top pivot                                                                                   WIRE TO
                                                                                                                     UPPER
arm. Make sure there is some                                                                                         PIVOT
slack in wire for movement dur-                                                                  SELF                ARM
ing operation.                                                                                   LOCKING
                                                                                                 NUTS (2)          WIRE
                                                                                                                   SHOWN ON
                                                                                                                   PIVOT
                                                                                                                   ARMS WITH
        IMPORTANT:                                                                                                 SLACK FOR
                                                                                                                   FREE
VISUALLY INSPECT THE                                                   WIRE SHOWN                                  MOVEMENT
CLEARANCES OF THE MOTOR                                                LOOPED AROUND
                                                                       PIVOT SPACER
PIVOT ARMS, AND WIRING TO
MAKE SURE THEY HAVE A
CLEAR PATH TO OPERATE. IF
THERE ARE OBSTRUCTIONS
MAKE ADJUSTMENTS NOW.                                                               FIGURE 3
                                                               -2-
STEP 8: ELECTRIC MOUNTING INSTRUCTIONS
                DUAL POLE
                PLUG

    DUAL POLE
    SOCKET
                              INSERT WIRE
                              RETAINER CLIP
                              IN PLUG AS
                              SHOWN                                                      BLACK TO
                  USE SET SCREW                                                          OPEN
                  TO ANCHOR
                  WIRE TO PLUG
                  RECEPTACLE                                                             GREEN TO
                                                                                         CENTER
  HD DUAL POLE CONNECTOR
                                                                                         WHITE TO
14 GA. WIRE                         SR
                                      T-2
                                                                                         CLOSE
FROM SWITCH
TO SOLENOID                                                                              FRONT OF
NEAR                                                                                     BRACKET
BATTERY

                                                                        ROCKER
                                                                        SWITCH AND
                                                                        MOUNTING
       SOLENOID                                                         BRACKET                                SELF
                                                                        INSIDE CAB                             DRILLING
                                                                                                               SCREW
                                                  CIRCUIT
                                                  BREAKER
                                                  40 AMP
                                                                                                       FIGURE 5


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.)
                                                                FIGURE 4



A. WIRE ROUTING - 6 GAUGE
Find the best route for the wire (usually along the frame with other wire har-
ness). Allow enough wire to reach inside the cab to the switch plate, then run
wire to the front of the box, allowing enough wire to reach up to the electric            1/2 EYELET FOR (+) BATTERY POST
motor. See Figure 4. Next mount the dual pole connector to a suitable location            3/8 EYELET FOR (-) BATTERY POST
                                                                                          5/16 EYELET FOR SOLENOID, CIRCUIT
on the semi-tractor, usually adjacent to the existing plugs. Then connect the             BREAKER AND MOTOR TERMINALS
wires to the socket using eyelets and heat shrink seal as shown below. If neces-
sary drill out hole in eyelet to fit socket. In the plug, disassemble the insert, feed
wire through plug, into brass contacts and crimp securely. Then tighten insert                         TYPICAL FOR ALL 6 GA.
                                                                                                       WIRE EYELETS
screws and set screw on plug housing.                                                              ”
                                                                                                5/8      TYPICAL HEAT
B. SWITCH LOCATION AND INSTALLATION                                                                      SHRINK TUBE FOR
Select convenient location in cab to mount switch bracket with two self                                  ALL 6 GA. WIRE
drilling screws through slots in back of bracket. See Figure 4 and 5.                                    CONNECTIONS


Route 14 ga. wire from switch to location of solenoid at 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 connec-
tors and crimp. Pull wires through mount bracket and attach to switch. See               RUBBER TERMINAL
Figure 4. Push switch into mount bracket until it snaps (locks) onto bracket.            BOOTS FOR SOLENOID
                                                                                         CONNECTIONS ONLY
C. PREPARING 6 GAUGE WIRE CONNECTOR ENDS
At batttery, begin prepping wire ends for battery post connectors. See Figure
6. Also shown is wire prepping for 6 gauge wire to solenoid and circuit break-
er terminals. Before cutting and prepping these wire ends for solenoid, pro-                     FIGURE 6
ceed to mounting the solenoid Step 8, page 4. Then determine wire lengths,
cut and prep the ends as shown in Figure 6 of this page.

                                                                  -3-
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