universal super shield & ultimate aluminum w/electric ......universal super shield &...

Universal Super Shield & Ultimate Aluminum w/Electric DriveConversion Kits 501-0732, 501-0734, 501-0735

Installation Instructions1404 N. Marshall Ave. El Cajon CA. 92020

For technical support call us at (800) 368-3075 or visit our website at PullTarps.com.

607-0026

WLH 09/19/16 111-0215 & 112-0215

For technical support call us at (800) 368-3075 or visit our website at PullTarps.com.

Conversion Kit-Universal Super ShieldInstallation Instructions1404 N. Marshall Ave. El Cajon CA. 92020

i

TABLE OF CONTENTS

Mounting Positions ...............................................................

Removing Tarp & Welding System to Truck .........................

Dimple Tailgate & Weld Tarp Return Ramps.........................

Rope Storage Hook Installation.............................................

Optional Flap Tarp, Rope and Hook Installation....................

Bungee Cord Installation.......................................................

1

2

3

4

5

6

7

8

9

11

13

14

Electric Motor Wiring & Plug Assembly.......................................

Electric Motor & Breaker Wiring..................................................

Special Instructions for ED Electric Conversion Kit....................

Special Instructions for Electric Drive Conversion Kit.................

Housing Assembly for 111-0215 USS with Electric Drive............

Housing Assembly 112-0215 UA with Electric Drive...................

***Assembly*** ***Wiring, Conversion Kits & Diagrams***

For technical support call us at (800) 368-3075 or visit our website at Pulltarps.com.



1

Fig. 1

"A" Mount

"D" Mount

"B" Mount

"E" Mount

"B" BracketsNOTE: Use optional "B" Brackets when mounting in position "B" and "E".

"C" Mount

"F" Mount

Fig. 4

Fig. 2

Fig. 5

Fig. 3

Fig. 6

Mounting PositionsStep 1: Determine the mounting position for your truck Fig. 1 - Fig. 6.




2

Removing Tarp & Welding System to Truck

System Assembly Fig. 8A & 8B

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.

Weld Mounting Bar to Truck

Fig. 7A

Fig. 8A

Fig. 7B

Fig. 8B




3

Dimple Tailgate & Weld Tarp Return RampsStep 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 thetailgate 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” diam-eter 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).

Step 4. Weld on Tarp Return RampsThe 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. 9

Fig. 11 Tarp Return Ramp Tarp Return Ramp Tarp Return Ramp

Hinge Ramp Gusset

Fig. 12 Fig. 13

Fig. 10




4

Rope Storage Hook InstallationStep 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).

Note: Tarp must be retracted when dumping

Fig. 14

Rope Storage Hooks

Rope StorageHooks

Fig. 15




5

Optional Flap Tarp, Rope and Hook Installation

Parts:

Tie Down Hooks (Steel or Alum.)

Pull Down Hook

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.

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 ground3. (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.

Note: The Location Of The Tie Down Hooks Is Critical!

Fig. 16

Fig. 18

Fig. 17

CORRECT

INCORRECT

Fig. 19




6

Bungee Cord Installation

Step 7: After side hooks are installed, the tie down rope must be in-stalled 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.

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).

Flip the rope back on top of the tarp, mak-ing 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).

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).

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.

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.

Tarps with Tie Downs

Snap Clip Installation

Excess Rope

Tarps with Side Flaps

Connect Bungee Cord to Rope1.

2.

3.

Fig. 20

Fig. 24

Fig. 25Fig. 21

Fig. 22 Fig. 23

Note: First snap clip should not be used on long wheel base belly dumps.

Parts:

2 Bungee Cords

2 Oval Compression Sleeves

1 Snap Clip

Top View

Tailgate

1st Snap Clip

2nd SnapClip




7

Electric Motor Wiring & Plug Assembly

Step 9 - Wiring: Assemble the Quick Disconnect as shown (Fig. 27).

6 ga. 1/4" LugConnector(part # 514-0308)

Terminal #1

Terminal #2

5/8"

Step 10: Crimp or solder pin to wire (Fig. 28).

Note: Make sure the pin snaps over the end of the spring tab.

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.

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.

Wire PinConnector

Spring Tab

Fig. 27

Fig. 28Fig. 29

Fig. 30

Battery Breaker

SwitchDump Pivot

Trailer Connector*

Fig. 26 * Trailer Connector Detail




8

Electric Motor & Breaker Wiring

30 Amp "Non Cycle" Breaker Note: Mount as close as possible to power

supply. To reset, disconnect power.BatteryMotor

- To Ground

6 ga. wire

14 ga. wire

Light

25 Amp“Push To Reset”Circuit Breaker

14 ga. wire

6 ga. wire

BatteryAux

Fig. 34 Motor Forward & Reverse Switch

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.

Fig. 31

Fig. 33

Fig. 32

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!

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.

Wiring Diagram (Fig. 34)

6 ga. 1/4" Lug Connector(part # 514-0308)

6 ga. #10 terminal ends(Part # 514-0307)

5/8"

To motor




9

BY

To Increase Tension1. Pull tarp out as far aspossible and tie off at tailgate2. Remove Ratchet Lock. Turnratchet nut clockwise 5 turnsat at time.3. Test operation and repeat steps 1 through 3 if necesary.

WARNING:Physical harmcould occur ifall tension is not removed before removing this plate.

To Disengage Lever,Remove Ratchet Lock &Insert Screwdriver Here

Install Ratchet Lock here

To Decrease Tension:1. Remove RatchetLock. Place boxend wrench onratchet nut. Turnratchet nut slightyto 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 Rachet Lock.

Special Instructions for ED Electric Conversion Kit (Conversion Kit to add electric Drive to existing housing)Step A. Removing the SpringRemove 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 HousingSlide the tarp out of the roller tube through the slotted end plate (opposite side as ratchet) (Fig. 1A).

Step C. Releasing the Spring Tension on the Roller Assembly1. 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 PlateRemove the four screws from the ratchet cover plate and carefully take the plate off.

Step E. Remove the Roller TubePull the entire roller tube assembly out the side of the housing (Fig. 3A).

Step F. Removing the Spring Assembly1. 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. 1A

Fig. 2A

Fig. 3A Fig. 4A

Ratchet Cover Plate

Insert 3/8"Bolt




10

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 I: Universal Super ShieldInstall motor as shown below (Fig. 7A).

Step J: Tarp InstallationSlide Tarp into groove on Roller Tube and center (Fig. 8A).

NOTE: See Switch Kit for Wiring Instructions.

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

3/8"

Fig. 6A Dimple

Roller Tube

Roller End Cap

Fig. 7APart# EHW35(3 REQ.)5/16-18 X 1” HHCS BOLT

Part# EHW34(1 REQ.)5/16-18 X 1 3/4” HHCS BOLT

Part# 31(1 REQ.)5/16-18 NYLOCK NUT

Part# P65/16LW(3 REQ.)5/16” LOCK WASHER

Part# P4AD1(1 REQ.)ADAPTOR PLATE

Fig. 8A




11

BY

To Increase Tension1. Pull tarp out as far aspossible and tie off at tailgate2. Remove Ratchet Lock. Turnratchet nut clockwise 5 turnsat at time.3. Test operation and repeat steps 1 through 3 if necesary.

WARNING:Physical harmcould occur ifall tension is not removed before removing this plate.

To Disengage Lever,Remove Ratchet Lock &Insert Screwdriver Here

Install Ratchet Lock here

To Decrease Tension:1. Remove RatchetLock. Place boxend wrench onratchet nut. Turnratchet nut slightyto 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 Rachet Lock.

Special Instructions for Electric Drive Conversion KitStep A. Removing the SpringRemove 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 HousingSlide the tarp out of the roller tube through the slotted end plate (opposite side as ratchet) (Fig. 1B).

Step C. Releasing the Spring Tension on the Roller Assembly1. 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 PlateRemove the eight screws from the ratchet end plate and remove (Fig. 3B).

Step E. Remove the Roller TubePull the entire roller tube assembly out the side of the housing (Fig. 3B).

Step F. Removing the Spring AssemblyA. 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. 1B

Fig. 2B

Fig. 3B Fig. 4B

Insert 3/8"Bolt

Ratchet Cover Plate




12

Special Instructions for Electric Drive Conversion KitStep 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 I: Universal Super ShieldInstall motor as shown below (Fig. 7B).

Step J: Tarp InstallationSlide Tarp into groove on Roller Tube and center (Fig. 8B).

NOTE: See Switch Kit for Wiring Instructions.

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

7/8"

Fig. 6B Dimple

Roller Tube

Roller End Cap

Fig. 7B Fig. 8B




13

Housing Assembly for 111-0215 Universal Super Shield With Electric Drive

Pullrod Hardware

ITEM PART # DESCRIPTION QTY1 501-01XX SS Housing 9.5" x 80,84,87,89,93,96,100"lg. 12 501-13XX Roller Tube Assy 80,84,87,89,93,96,100"lg. 13 501-15XX Mounting Bar-Steel, 40,42,43.5,44.5,46.5,48,50"lg. 24 505-2502 1/4" Flat Washer USS 15 503-3108 5/16"-18 x 1 3/4"lg. HHCS Bolt 16 503-3105 5/16"-18 x 1"lg. HHCS Bolt 37 503-3101 5/16"-18 x 1/2"lg. HHCS Bolt 128 505-3102 5/16" Lock Washer 159 504-3103 5/16"-18 Nyloc Nut 1

10 506-9905 #10-32 x 1/2"lg. Phillips Head Pan 411 501-1235 Alum. Adaptor Plate - SW Motor 112 501-0632 System End Plate Stud Kit 113 501-1506 6" Large Steel Mounting Bracket 214 517-0906 12V DC Electric Motor 1--- 514-0201 6 GA. Electric Wire (Not Shown) 100'--- 514-0505 Gray Quick Disconnect (Not Shown) 215 607-0061 Pulltarps Decal 1

ITEM PART # DESCRIPTION QTY16 501-0301 Tarp Return Ramps (Steel) 2-- 501-0302 Tarp Return Ramps (Alum.) 217 501-0621 Rope Storage Kits (4 Steel Hooks) 1-- 501-0608 Rope Storage Kits (4 Alum. Hooks) 118 517-10XX Pull Rope (20, 25, 30, 35, 40, 50') 119 Determined

by Length Pullrod (85, 91, 93, 96, 100, 105" Lengths) 120 501-0612 Pullrod Hardware Kit 1

REV: 11/08/07 BAB

10

14

13 54

9

17

20

2

3

16

19

17

18

2012

13

12

11

8 6

15

1 87




14

Housing Assembly 112-0215 Ultimate Aluminum with Electric Drive

4

Pullrod Hardware

ITEM PART # DESCRIPTION QTY1 501-01XX Ultimate Aluminum Housing - 80, 84, 87, 89, 93, 96"lg. 12 501-13XX 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 16 501-0228 Ultimate Aluminum End Plate - Right Side 17 501-0803 System End Plate Stud Kit 18 517-0102 Flanged End Cap 19 501-9915 Roller Drive Aluminum End Cap 1

10 506-9916 Screw #8-18 x 3/4" Self Drilling 111 503-3105 5/16"-18 x 1"lg. HHCS Bolt 712 503-2502 1/4"-20 x 1/2"lg. SS BHCS 1613 504-3103 5/16"-18 Nyloc Nut 114 503-3108 5/16"-18 x 1 3/4 Hex Bolt 115 505-2502 1/4" Flat Washer USS 716 505-3102 5/16" Lock Washer 1517 503-3101 5/16"-18 x 1/2"lg. HHCS Bolt 818 607-0061 Pulltarps Decal 119 517-0906 12V DC Electric Motor 1

ITEM PART # DESCRIPTION QTY20 501-0301 Tarp Return Ramps (Steel) 2-- 501-0302 Tarp Return Ramps (Alum.) 221 501-0621 Rope Storage Kits (4 Steel Hooks) 1-- 501-0608 Rope Storage Kits (4 Alum. Hooks) 122 517-10XX Pull Rope (20, 25, 30, 35, 40, 50') 123 Determined

by Length Pullrod (85, 91, 93, 96, 100, 105" Lengths) 124 501-0612 Pullrod Hardware Kit 1

REV: 09/19/16 WLH

19 5

1511

1218 3

1 12

6

7

1116

15

10

1716

4 149

16 13

2

21

20

21

22

248

23

24

universal super shield & ultimate aluminum w/electric ......universal super shield &...

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