EGR RollTrac User manual

RT0001 Date: 08/04/20 Issue: 5 Page: 1 of 12
OWNER’S MANUAL
ELECTRIC
IMPORTANT: PLACE IN THE CUSTOMER’S VEHICLE SERVICE BOOK
rt0001
id#117035

Thank you for purchasing this EGR RollTrac.
Read this owner’s manual thoroughly before using this accessory and follow the instructions for use.
This product must be installed exactly as specified in the installation instructions. Failure to do so may
result in improper fit and/or retention and loss of warranty.
Introduction............................................................................................................................................2
EGR RollTrac main components...........................................................................................................2
Warnings - Safety..................................................................................................................................3
Warranty terms......................................................................................................................................4
Maintenance..........................................................................................................................................4
Calibration procedure............................................................................................................................5
Opening and closing procedure.............................................................................................................6
Locking Procedure.................................................................................................................................7
Interior light operation............................................................................................................................8
Cleaning canister...................................................................................................................................8
FAQs.....................................................................................................................................................9
Trouble Shooting............................................................................................................................10-11
Key identification code.........................................................................................................................12
Installation checklist.............................................................................................................................12
FRONT COVER
EGR RollTrac MAIN COMPONENTS
SIDE RAIL
TAILGATE RAIL
SLATS
SIDE RAIL
CANISTER
SERVICE COVER
CANISTER
Introduction.
RT0001 Date: 08/04/20 Issue: 5 Page: 2 of 12
Contents.
HAND RAIL
ASSEMBLY

Do not use the tub as a passenger compartment. In case of accidental entrapment. First disengage the
motor by depressing the phosphorescent clutch release lever located near the motor housing (front of
vehicle tub). Secondly twist the phosphorescent hand rail lock release located at the centre of the hand
rail (rear of vehicle tub) - Cover will now retract.
Do not store or transport volatile materials, such as solvents, chemicals or liquids as fumes may
accumulate inside tub. Do Not allow solvents, chemicals or oils to come in contact with the
EGR Roll Trac. If this should occur clean the EGR RollTrac immediately with a mild detergent and water
solution.
Do not stand/sit or rest heavy objects on EGR RollTrac.
Do not fill or store volatile liquid containers such as fuel cans while under the EGR RollTrac.
VEHICLES FITTED WITH A BED LINER: Static electricity can cause fire when fuel is pumped into
ungrounded fuel containers or equipment (eg: motorcycles, chainsaws etc..). Do Not fill fuel
containers or equipment within the vehicle tray as static electricity can cause fuel to ignite, resulting in
damage, injury or death. To avoid electricity build-up, place fuel container or equipment on the ground
before filling.
Do not drive the vehicle with the motor clutch disengaged – free moving roll cover may move causing
injury or damage to property whilst driving.
The cover is designed to be water and dust resistant in the majority of situations, in certain extreme
environments a certain level of ingress is to be expected. Items that are of high value and are suscepti-
ble to water damage should be packaged accordingly. Condensation on the under side of the cover
should be expected under certain conditions (cool days / nights).
Do not subject the slats/hand rail to excessive open/close forces, excessive force may damage internal
components replacement of which may not be covered in your warranty.
While the EGR RollTrac has a built in safety feature to prevent damage and injury, you must keep
obstructions clear of cover during opening/closing.
Warnings - Safety!
RT0001 Date: 08/04/20 Issue: 5 Page: 3 of 12
•
•
•
•
•
•
•
•
•
•
WARNING
KG
KG
150kg
150kg
TOTAL
TOTAL
1000 km
To ensure your electric EGR Rolltrac continues to operate in a trouble free manor we recommend to
recalibrate the cover every 6 months. This interval may be reduced if you notice any irregularities when
opening or closing the cover.

Your EGR RollTrac is designed for years of Maintenance free operation, however in certain conditions
additional care may be required to ensure smooth operation. If the vehicle is driven in extreme condi-
tions (hot/cold/dust) then maintenance intervals will have to be reduced.
Regularly wash the cover, Only use mild detergents, liquid wax or general purpose cleaner’ to clean
EGR RollTrac. Avoid the use of products containing alcohol as these can damage the painted surface.
Do Not use abrasive compounds on painted or plastic finished cover surfaces.
Only locks and lock recesses are to be lubricated with Graphite Powder.
DO NOT use any other lubricants or oils. Using alternative products will VOID Warranty.
It is recommended to check EGR RollTrac attachment clamps every 1000 km (more often in harsh
driving conditions).
Clamp bolt recommended torque settings are specified in your EGR RollTrac installation instruction.
If removed, bolts must have LOCTITE 243 re-applied and be re-tightened to specified values.
Regularly open inspection covers and remove any Debris from canister – hose with water to wash
debris from canister and ensure water flows freely from drain tubes.
Regularly inspect all four drain tubes for damage or splitting.
Regularly clean side rail seal, side rail glide strips and canister drive plates with water and mild deter-
gent.
If you notice Slow, Heavy or Noisy operation of the cover firstly clean the externals of the EGR RollTrac
(Slats, Side rails, Seals etc,) and the internals of the canister as described above. Allow product to dry
thoroughly. With service covers open and slats in fully closed position apply a coat of plastic compatible
100% liquid silicon spray to the spiral shaped internals of canister endplates ONLY. Open and close the
cover several times to ensure lubricant is dispersed over all moving parts. Reassemble Refit service
covers and recalibrate product if required. DO NOT use any other lubricants or oils. Using alternative
products will VOID Warranty.
RT0001 Date: 08/04/20 Issue: 5 Page: 4 of 12
Maintenance.
Warranty Terms.
•
•
•
•
•
•
•
•
•
This warranty only applies to the original purchaser and is non-transferable. Warranty must be claimed
with original sales receipt for proof of purchase. EGR warrants that the EGR RollTrac will be free from
defects in material and workmanship for a period of three (3) years from the retail date of purchase. War-
ranty claims are to be lodged via place of purchase.
Exclusions:
This warranty does not cover failure due to neglect, improper installation, including any modifications to
installation hardware, alterations, addition of non genuine equipment, abuse, accident, normal wear and
tear, lack of maintenance, misuse, and exposure to chemicals that are not safe for plastics or hardware
components.
Incidental or consequential damage or loss of contents due to use, neglect, lack of maintenance, misuse
of EGR RollTrac is sole responsibility of the vehicle owner and operator. Paint wear and panel damage
due to (clamping / installation) on the vehicle bed can happen with EGR RollTrac and is the sole responsi-
bility of the vehicle owner. Paint and panel damage to your vehicle is not covered under this warranty.
Disclaimer:
In the event that your EGR RollTrac is found to be defective under the terms of this warranty, it is at the
discretion of EGR to repair or replace the defective part. Transportation costs and fitment labour are not
associated with this warranty claim.

RT0001 Date: 08/04/20 Issue: 5 Page: 5 of 12
Calibration Procedure
PULL
2
1
L
O
C
K
A
C
C
O
N
S
T
A
R
T
P
U
S
H
4
310 SECONDS
!
START OF CALIBRATION
END OF CALIBRATION
1 2 3
4 5 6
2 SECOND PULSE
DURING CALIBRATION
• Cover will open and close twice automatically.
• The cover internal LED light will pulse slowly during calibration and stop pulsing when
calibration is complete.
1. Start the vehicle in an open area (note exhaust fumes are a health and safety hazard!).
2. Open the tailgate.
3. Ensure the motor clutch is engaged.
4. Ensure car doors are unlocked and disable auto-locking during calibration procedure.
Press the two side rail buttons simultaneously for 10 seconds to START calibration mode.
WARNING: Keep obstructions clear of cover during calibration mode.

RT0001 Date: 08/04/20 Issue: 5 Page: 6 of 12
Locate the Clutch Disengagement Lever on the RH side of the cover and push the Clutch inward to
disengage the motor. Pull the cover rearward or forward as required. Before driving vehicle ensure you
re-engage the clutch.
IMPORTANT: If clutch was disengaged, callibration procedure needs to be re-run prior to electric
operation.
CLUTCH
PUSH
CLUTCH
ENGAGED
CLUTCH
DISENGAGED
Opening and Closing Procedure
Electric Closing Procedure:
Electric Opening Procedure:
Manual Opening and Closing Procedure:
NOTE: Cover should open and close smoothly. If cover does not lock or open correctly, please
refer to the trouble shooting section.
UNLOCK
OPEN
PRESS ONCE
1. Press the “UNLOCK” button on the car remote.
2. Press the front button on the EGR RollTrac side rail as shown.
1. Press the rear button on the EGR RollTrac side rail as shown.
2. Press the “LOCK” button on the car remote.
CLOSE
PRESS ONCE
1 2

RT0001 Date: 08/04/20 Issue: 5 Page: 7 of 12
Emergency Opening:
1. In case of entrapment inside a locked vehicle tub fitted with EGR RollTrac, release the motor clutch by
pushing in the Clutch Disengagement Lever (on the RH side of the cover).
2. Turn the emergency release handle located on the centre of the hand rail assembly and retract the
slats manually.
TURN HANDLE
PUSH
Locking Procedure
Manual locking / unlocking using key:
Electric locking / unlocking using key:
1. Ensure cover is fully closed.
2. Open the rubber cap covering the lock and using the provided key turn RIGHT to lock and LEFT
to unlock the cover.
3. Check lock engagement by opening the tailgate, if lock does not engage recheck cover installation.
UNLOCK LOCK
1. Ensure cover is fully closed.
2. Lock or unlock the cover by using button on the key remote.
3. Check lock engagement by opening the tailgate, if lock does not engage recheck cover installation
NOTE: If vehicle is locked, buttons are deactivated and cover will not open/close.
Lock latches will not activate untill cover is in fully closed position.
Ensure to return tailgate to fully closed position prior to lock/unlock.
1. 2.

RT0001 Date: 08/04/20 Issue: 5 Page: 8 of 12
The interior light has 3 settings activated by pushing the button on the side.
Each button press cycles from:
1. AUTO (default) which turns light off 2 mins after last button press.
2. ON - Light remains on for 20 mins
3. OFF
1. The canister has two or one (depending on model) inspection points for cleaning any leaves
and debris collected inside the canister.
2. With the cover open, unscrew the screws holding the inspection cover to gain access to the
canister.
3. Remove all larger debris and use a brush or hose with water to remove any small particles.
PUSH THE
BUTTON
Small blue LED
light indicates
auto mode
INSPECTION
COVER
INSPECTION
COVER
Interior Light:
Cleaning the canister:

RT0001 Date: 08/04/20 Issue: 5 Page: 9 of 12
FAQ’s:
Which EGR RollTrac accessories fit my vehicle?
All major racking brands will work on the EGR RollTrac. Rhino, Thule, Yakima, Rola, should all be
able to adapt and integrate into our side rail channeling.
Other accessories include EGR’s own Sports BarAdaptor Kits and Dust Defense Kits, as well as
extra LED lighting.
What is the warranty period on EGR RollTrac?
We provide a 3-year limited warranty for the original consumer that warrants the product to be free
from material or workmanship defects.
Labour charges associated with removing or re-installing the product and parts are not covered with
this warranty.
What do I do if I have a warranty issue with my EGR RollTrac?
In the instance of lodging a warranty claim, please return to the place of purchase or fitment, and
lodge with them directly, as essentially, they sold you the product.
They will then claim on EGR.
EGR will request the following (perhaps provide it to your place of purchase to save processing time)
- Product & Part Number
- Description of the warranty issue
- Copy of original receipt
- Images of the issue and serial number label
What is the load capacity of EGR RollTrac?
EGR RollTrac has a top load capacity of 150kg, however you may be restricted by the rack company
product load capacity. Some provide higher loads on their items than others.
Are spare parts available for EGR RollTrac?
EGR have a range of service kits for interchangeable parts on EGR RollTrac.
Do I need to drill holes in the vehicle body when installing EGR RollTrac?
Whilst the EGR RollTrac fits to the vehicle using a clamp system, there is drilling required to fit the
tailgate rail and drain tubes.
Can I install EGR RollTrac myself?
Yes, but please review the fitting instructions prior to ensure you have all the required skills and
correct tooling to undertake the fitment. It is recommended to use an EGR Distributor for the fitment
as they will have this tooling, and be fluent in our product range already.
Is EGR RollTrac compatible with tub liners?
Yes, with some modification required. Trimming requirements are explained in the fitting instructions
for each product.
Can I download a copy of the EGR RollTrac fitting instructions?
Yes, nd downloads and make contact with the EGR RollTrac customer service team via:
http://www.egrrolltrac.com

RT0001 Date: 08/04/20 Issue: 5 Page: 10 of 12
FAULT ACTION
EGR RollTrac
does not
operate when
buttons pushed
(opening or
closing) Check for mechanical obstructions that prevent the slats running smoothly (check this by disengaging
the emergency clutch release and manually opening and closing cover). Recalibrate afterwards.
Do LED lights operate when button is pushed? If yes this indicates the unit has power, if no then
recheck all battery and harness connections.
Open inspection covers and remove any obstructions inside canister, hose with water to wash any
smaller debris from canister, ensure water flows freely from drain tubes.
Remove power (fuse) and wait for 5 sec. before applying power back to RollTrac and recalibrate.
Error mode is indicated by flashing LED lights and loss of function mid operation, follow steps as outlined
above.
Manually lock and unlock using the key, recheck operation.
Was Calibration run successfully? If not refer to calibration troubleshooting.
Check vehicle is unlocked.
EGR RollTrac
is not running
through
complete
calibration
cycle
(complete
close and
open x2) Do LED lights operate when the LED button is pushed? If yes this indicates the unit has power, if no
then recheck all battery and harness connections.
Prior to calibration check cover operates manually (check this by disengaging the emergency clutch
release and manually opening and closing cover), if cover does not operate check for mechanical
obstructions and check installation as outlined in the Installation Instruction.
Check components for secure mounting, debris or damage.
Follow Calibration procedure, ensure tailgate is open and vehicle is parked on a level surface when
running calibration.
Check components for secure mounting, debris or damage.
With cover fully closed and tailgate down check operation of lock latches using key fob and key.
Ensure both buttons are depressed for the full 10 seconds, if calibration is not successful using buttons
on one side of the vehicle then retry on the opposite side.
Ensure tailgate is open and vehicle is parked on a level surface when running calibration.
EGR RollTrac
locking is
not locking/
unlocking
tailgate In certain cases vehicle tailgate may be too high relative to tub side rails. Cover can be lifted by appli-
cation of additional layers of protective film along tub sides.
Slat assy
does not
open/close
smoothly or
completely
Ensure all foreign debris such as rocks, sand, leaves, frost or ice etc are not present on the top slat
surface or in the side rail tracks.
In frosty environments ice should be removed from the cover using cold water and a soft scraper prior
to operation.
Open inspection covers and remove any Debris from canister – hose with water to wash debris from
canister and ensure water flows freely from drain tubes.
Trouble Shooting.
If at closed position gently pull handrail back fully into rear corners and push the OPEN button.
Ensure that cover is cleaned and lubricated as described in the owners manual maintenance section.
Ensure that cover is cleaned and lubricated as described in the owners manual maintenance section.
Cover must be recalibrated (to reset end stop locations) every time cover is operated manually /
motor clutch is disengaged.
Check that the hand rail has side to side movement in open / close position, if not check and adjust
installation as outlined in the Installation Instruction.
Check position of cover on tub (Vertical position of tailgate rail relative to handrail and front to back
position of side rail rear corner blocks relative to tailgate rail) as outlined in the installation instruction.

Refer to your authorised EGR RollTrac dealer for further information.
Specifications are correct at time of printing and are subject to change without
notice or obligation.
RT0001 Date: 08/04/20 Issue: 5 Page: 11 of 12
Indicates low battery voltage, check battery condition.
LED lights
do not
switch
on/off
Lights flicker
with slow
open/close
If Roll Cover is operational - Check connections to LED light in side rail are pushed home.
Check light operation in previous section of the Owners Manual.
If EGR RollTrac is not operational – lighting is linked to installation of vehicle harness and connectors,
troubleshoot and recheck operation.
FAULT ACTION
Dust ingress
in tub
Water ingress
in tub
From the factory vehicle tubs have various openings (to allow for water drainage etc). Ensure these
openings are properly sealed to prevent dust ingress.
Check all seals are present and undamaged.
Ensure rubber drain tubes are properly seated to holes in tub.
In certain cases (twisted tub) additional layers of foam tape may be required on the tub header rail to
ensure a good seal.
The cover is designed to be water resistant in the majority of situations, in certain extreme environ-
ments a certain level of water ingress is to be expected. Items that are of high value and are suscep-
tible to water damage should be packaged accordingly.
From the factory vehicle tubs have various openings (to allow for water drainage etc). Ensure these
openings are properly sealed to prevent water ingress.
Check all seals are present and undamaged.
Ensure rubber drain tubes are properly seated to canister cover (twisting these tubes will ensure
proper seating in canister body) tub and rear corner pieces.
Ensure front drain tubes have been trimmed to suit tub/liner combination, if tubes are too long water
flow may be reduced.
In certain cases (twisted tub) additional layers of foam tape may be required on the tub header rail
etc to ensure a good seal.
Open inspection covers and check that front drain tubes are installed correctly, hose with water to
wash any debris from canister and ensure water flows freely from drain tubes.
Noisy
operation Check all fastners are torqued.
Ensure EGR RollTrac is cleaned as per Maintenance instructions.
Ensure all foreign debris such as rocks, sand, leaves etc are removed.
Trouble Shooting continue.
After periods of non use the seals on your roll track may cause a thumping sound on first opening or
closing - This is a function of the seal design and does not indicate a fault. Operation noise should
return to normal after regular operation.

Dealer Name & Code: Car Model and Rego:
Order Date:
Required By:
Installation Checklist:
EGR RollTrac - KEY ID CODE:
Vehicle Damage Check: Detail:
Stock No:
Vin No:
Comments:
EGR RollTrac Serial Number:
Checked By:Fitted By:
INSTALLATION CHECKLIST
1234
Please write the key identification code in the boxes above,
and retain this copy with the vehicle service history.
Replacement keys can be purchased from your local dealer.
KEY IDENTIFICATION CODE
CHECK
RollTrac sealing evenly to tray/tub
Position EGR RollTrac correctly relative to tailgate rail and cab
Position EGR RollTrac on tub squarely and centrally
Clamps are square and tight, torqued as specified in your EGR RollTrac installation
instruction, side bolts and pads fitted.
Check that the clutch release lever functions correctly (must be done prior to calibration)
Water drainage pipes connected and in place (front and rear)
Test that lock latches lock and unlock with tailgate down and also when tailgate is up
Check cover moves from fully open to fully closed smoothly and quietly
Check anti pinch operates correctly
Check that emergency handle on hand rail opens lock latches correctly
Ensure all accessories are fitted as per manufacturers recommendations
Check LED lights operate
RT0001 Date: 08/04/20 Issue: 5 Page: 12 of 12
Installation Checklist.
Key Identification Code.
1
2
3
4
5
6
7
8
9
10
11
12