Shurco 4500 HD Series User manual

Aluminum Single-Arm System for
Open-Top Vans & Live-Bottom Trailers
P/N 1121522 Rev. F

P/N 1121522 Rev. A
Shur-Co®, LLC Terms & Conditions
SHIPPING. Orders are shipped F.O.B. from the Shur-Co®, LLC sites listed be-
low. No full freight isallowed or prepaid shipment accepted unless quoted and
approved in writing prior to acceptance of the order. All shipments are made
by the most reasonable means in accordance with size and weight of order,
unless specifi ed routing instructions are furnished by the customer. Shipments
are made daily via U.P.S. and common carrier. Claims for shortages must
be made within 10 days. All claims for damages or loss in transit must be
made with the carrier. No collect calls will be accepted. To ensure delivery of
orders, we need your full street address and phone number. When you receive
your shipment, examine it carefully. Be sure all cartons listed on the delivery
sheet are accounted for. Large items may be packaged separately. If a carton
is damaged, open it and inspect the contents before signing for delivery. If
merchandise is damaged, describe damage on the delivery receipt. Failure
on your part to document damaged or missing merchandise on the delivery
receipt releases the carrier of all liability; repair or replacement will be the
customer’s responsibility.
WARRANTY. We warrant all new products are free of defects in materials and
workmanship.* This warranty is effective if products are properly installed and
used for the purpose for which they were intended and applies to the original
buyer only. Except as set forth above or in any product-specifi c warranty docu-
mentation, we make no other warranties, express or implied, including but not
limited to warranties of merchantability of fi tness for a particular use.
Returns of a product for warranty must be accompanied by a Return Merchan-
dise Authorization number (RMA#), obtained by by calling Customer Service
at 866-748-7435, and sent, with freight paid by us, to Shur-Co®, LLC, 2309
Shur-Lok St., PO Box 713, Yankton, SD 57078. All products returned without
an RMA# will be refused. When we issue the RMA#, we will also issue a call
tag to have UPS (or other freight company) pick up the product. C.O.D. returns
not accepted. We will pay no storage fees for a warranty product return prior to
pick by us or the freight company. If a warranty product return is scheduled to
be picked up by us, we will pick up the product at our earliest convenience.
If a product returned is found, in our judgement, to be defective in material
or workmanship, our obligation under this warranty is limited to the repair or
replacement of the product, which will be made by us. Repair or replacement
will be at our discretion, with replacements being made using current products
performing in the equivalent function. Labor charges, other than those incurred
at our factory, including, but not limited to, any labor to install a repaired or re-
placement product, are not covered under this warranty. All expenses associ-
ated with delivering defective products to our factory and delivering repaired or
replacement products from our factory to the owner will be paid by us.
If the product returned is found, in our judgement, to be non-warrantable, the
owner will be contacted to authorize repair work, purchase of a replacement
product or return of the product, all of which will be at the owner’s expense.
Payment authorization must be received by us before any non-warrantable
product is repaired, replaced or returned. All expenses associated with deliver-
ing the repaired non-warrantable product, a replacement product or the non-
warrantable product from our factory to the owner will be paid by the owner.
In no event will we be liable for any damages of any kind to person, product or
property, including but not limited to indirect, incidental, special, consequential
or punitive damages, or damages for loss of profi ts or revenue, even if we
have been advised of the possibility of such damages. There are no warran-
ties for used products or products that have been repaired, altered, modifi ed
or subjected to misuse, negligence or accident. We will not repair or replace
products that fail or malfunction due to ordinary wear and tear, except as ex-
pressly noted in a product-specifi c warranty. Use of non-Shur-Co®, LLC parts
in conjuction with Shur-Co®, LLC products will void this product warranty.
*Certain products have specifi c warranties that differ from this warranty, for example motors and elec-
tronics. Product-specifi c warranty documentation is available for these items. In the event of a confl ict
between this warranty and a product-specifi c warranty, the product-specifi c warranty will govern.
RETURN POLICY. All sales fi nal. See WARRANTY above for return details.
OTHER. All prices, product listings, sizes, weights and manufacturing details
are subject to change without notice. No person is authorized to modify the
foregoing conditions of sale whatsoever.
SHUR-CO® of NORTH DAKOTA
1746 4th Ave. NW
West Fargo, ND 58078
Ph 877.868.4488 | Fax [phone]
SHUR-CO® of OHIO
1100 N. Freedom, St. Rt. 88 & 14
Ravenna, OH 44266
Ph 866.356.0242 | Fax [phone]
SHUR-CO® UK, Ltd.
Unit 41 Rochester Airport Estates
Laker Rd., Rochester, Kent ME1 3QX
Ph +44 (0)1795.473499
Fax [phone]
For more info, log on to our website:
www.shurco.com
Corporate HQ and Outlet Store
SHUR-CO® of SOUTH DAKOTA
2309 Shur-Lok St., PO Box 713
Yankton, SD 57078-0713
Ph 800.474.8756 | Fax [phone]
ShurTite™ Service Centers
SHUR-CO® of CANADA
490 Elgin St., Unit #1
Brantford, Ontario N3S 7P8
Ph 800.265.0823 | Fax [phone]
SHUR-CO® of SIOUX FALLS
47184 258th St., Suite B
Sioux Falls, SD 57107
Ph 844.573.9322 | Fax [phone]
SHUR-CO® of ILLINOIS
Ph 866.356.0246 | Fax [phone]
SHUR-CO® of OHIO
Ph 866.356.0242 | Fax [phone]
SHUR-CO® of FLORIDA
3353 SE Gran Park Way
Stuart, FL 34997
Ph 800.327.8287 | Fax [phone]
SHUR-CO® of ILLINOIS
3993 E. Mueller Ave.
Decatur, IL 62526
Ph 866.356.0246 | Fax [phone]
SHUR-CO® of IOWA
3839 Midway Blvd.
Ft. Dodge, IA 50501
Ph 866.356.0245 | Fax [phone]
SHUR-CO® of MICHIGAN
5100 Lakeshore Dr.
Lexington, MI 48450
Ph 800.327.8287 | Fax [phone]
SHUR-CO®, LLC SERVICE AND DISTRIBUTION CENTERS
P/N 1121522 Rev. F

Thank you for buying this tarping system from Shur-Co®. We appreci-
ate your condence in our products. Please read and thoroughly un-
derstand this manual before installing and/or operating this system.
Pay particular attention to important safety and operating instructions,
as well as warnings and cautions. The hazard symbol is used
to alert users to potentially hazardous conditions and is followed by
caution, warning or danger messages.
Failure to READ AND FOLLOW INSTRUCTIONS could result in fail-
ure of your tarping system and/or personal injury. Your trailer require-
ments may, however, call for minor variations to these instructions.
Please inspect your tarping system periodically, and repair or replace
worn or damaged parts.
QUESTIONS? CALL OUR HELP LINE:
1-866-748-7435
MON-FRI 8 AM-5 PM CENTRAL TIME
We at Shur-Co® are concerned with your safety and the safety of all
those operating this system. Therefore, we have provided safety de-
cals at various locations on your tarping system. Keep decals as clean
as possible at all times. Replace any decal that has become worn
or damaged, painted over or otherwise difcult to read. Replacement
decals are available through Shur-Co® dealers.
To prevent rust, paint all exposed metal, such as weld seams and/or
metal exposed by grinding or cutting, with corrosion-resistant paint.
4500 Series Aluminum Single-Arm System
P/N 1121522 Rev. F
Hardware Identication.......................................................................1
Pivot Bracket Installation ...................................................................2
Front Flex Arm & Electric Motor Installation ....................................3-4
Roll Tube Extension Installation ......................................................5-6
Stretch Cord Return............................................................................7
Shur-Return™ ....................................................................................8
Rear Cable Return..............................................................................9
Value Series Stretch Cord Return ....................................................10
Electric Mounting & Wiring ..........................................................11-15
Wireless SMARTransmitter® Operating ............................................16
Program Wireless SMARTransmitter®to Receiver...........................17
Electric Motor Replacement .............................................................18
Change from Electric to Manual Operation ......................................19
Replacement Parts......................................................................20-23
Troubleshooting Guide .....................................................................24
1. Welder
2. Hammer
3. Center Punch or Transfer Punch
4. #3 Phillips Insert Bit
5. Air or Electric Impact Wrench (9/16" deep socket)
6. 7/16" Deep Socket
7. 3/8" Combination Wrench
8. 9/16" Combination Wrench
9. 1/2" Combination Wrench
10. 1/8" Hex Wrench Long T-Handle
11. 3/16" Hex Wrench Long T-Handle (recommended)
12. 5/16" Drill Bit (for 3/8” self-tapping screws)
13. 11/32" Drill Bit
14. 13/32" Drill Bit
15. 3/8" Drill
15. 1 1/8" Hole Saw
16. 2" Hole Saw
17. Standard/Flathead Screwdriver
18. #2 Phillips Screwdriver
19. Utility Knife
20. Ratchet
21. Hack Saw (metal cutter)
22. Pliers
23. Snap Ring Pliers
24. Wire Cutters
25. Grinder
26. Tape Measure
!
TOOLS REQUIRED
RUST PREVENTION
SAFETY
MESSAGE TO OWNERS TABLE OF CONTENTS
1. Always wear safety glasses during installa-
tion and operation.
2. Stay clear of moving parts.
3. No other use of this system is authorized,
except as designed.
SAFETY INSTRUCTIONS

P/N 1121522 Rev. F
Hardware Identication
1
Inspect all parts in your 4500 Series Electric kit upon arrival.
1700411 Hex Nut - 5/16"
1700429 Flat Washer - 3/8"
1700400 Cap Screw - 3/8" x 1"
1700419 Nylon Lock Nut - 5/16"
1701045 Cap Screw - 5/16" x 3/4"
1700407 Hex Nut - 3/8"
1700434 Lock Washer - 3/8"
1118318 Spacer Washer - 1/4" x 1.81"
1702891 Cap Screw - 3/8" x 1 1/4"
1702890 Flat Washer - 1 1/4"
1701543 Nylon Lock Nut - 1/4"
1808844 Nylon Lock Nut - #10
1700427 Flat Washer - 1/4"
1703373 Flat Washer - 1/2"
1704057 Cap Screw - 3/8" x 2"
1704905 Flanged Cap Screw - #10 x 1"
1700398 Self-Drilling Screw - 1/4" x 3/4"
1702926 Cap Screw - 5/16" x 7/8"
1700428 Flat Washer - 5/16"
A
B
C
D
E
F
G
H
J
K
L
N
O
P
Q
R
S
T
V
W
Y
X
Z
AA
1120291 Pivot Bracket Washer
1700403 Self-Tapping Screw - 1/4" x 3/4"
1704338 Self-Tapping Screw - 1/4" x 1"
1704367 Cap Screw - #10 x 3/4"
1700408 Hex Nut - 1/4"
1700436 Lock Washer - 1/4"
1701580 Nylon Lock Nut - 3/8"
M
1704743 Self-Drilling Screw - #10 x 1/2"
1701423 Set Screw - #10 x 3/16"
1700717 Eyebolt - 5/16" x 7/8"
1704946 Flanged Top Lock Nut - 5/16"
U
1704353 Self-Drilling Screw - 1/4" x 1"
1700736 Self-Tapping Screw - 1/4" x 1/2"
1700433 Lock Washer - 5/16"
BB
CC
DD
EE
FF
GG
HH

P/N 1121522 Rev. F Pivot Bracket Installation
2
rivets off
center
front of trailer
STEP 1: Locate front pivot mount bracket on passenger side
of trailer so center of pivot lies within shaded area
shown below. Measure 41" down from top of cap or
43" from top of windshield.
4"
4" 4"
4"
6"
4"
4"
6"
rivets on
center line
43"
c
l
locate center
of pivot inside
shaded area
STEP 2: Place pivot mount brackets on trailer in orientation
shown below. Using brackets as guide, mark mounting
hole locations.
N
rivets/corrugation off center
rivets/corrugations on center
center of
trailer
NOTE: Read entire section before drilling holes. Determine if
rivets on front of trailer are centered or off center.
NOTE: Mount front pivot bracket into support braces on trailer
if possible. If bracket cannot be mounted into support braces,
reinforce mounting area with backer plate for adequate support.
Before drilling any holes, make sure ex arm will have clear
pathway to operate.
Item Part # Description
1. 1116920 Pivot Pin - 4 Spring
2. 1116919 Vertical Pivot Mount Bracket - 7 1/4" Standoff
1117927 Vertical Pivot Mount Bracket - 12 1/4" Standoff
1117767 Pivot Mount Bracket - 1 1/4"
3. 1120361 Pivot Backer Plate - 5" x 16"
1120418 Pivot Backer Plate - 5" x 20"
N. 1702891 Cap Screw - 3/8" x 1 1/4"
V. 1700407 Hex Nut - 3/8"
CC. 1700434 Lock Washer - 3/8"
DD. 1700429 Flat Washer - 3/8"
pivot bracket pivot pin
STEP 1: Fasten pivot pin to pivot bracket with keyway facing
downward as shown.
Keyway in pivot pin must
face downward.
PIVOT PIN INSTALLATION
31
STEP 3: Remove rivets and mount brackets into rivet holes. If this
is not possible, drill 13/32" holes in trailer. Fasten with
screws
N
, at washers
DD
, pivot bracket washers
CC
, lock washers
HH
and nuts
W
.
2
c
l
c
l
c
l
2
41"
N
N
W
W
NOTE: Use pivot bracket washers only when horizontal
corrugation on trailer skin prevents bracket from contacting skin.
STEP 3: If installing pivot bracket or pivot mount bracket on
horizontally corrugated trailer skin, center bracket
between corrugations and use brackets as guide to
mark hole locations. Mark and drill 13/32" holes in
trailer and fasten with screws
N
, at washers
DD
, lock washers
CC
, pivot bracket washers
HH
and
nuts
W
. Locate pivot bracket washers between pivot
bracket and trailer skin as shown.
N
pivot bracket
corrugated trailer skin locate pivot bracket
washers between pivot
bracket & trailer skin
horizontally corrugated trailers
W
N
W
W
CC
CC
CC
CC
CC
DD
DD
DD DD
DD
DD
DD
HH
HH
HH

P/N 1121522 Rev. F
3
Front Flex Arm & Electric Motor Installation
1
pivot mount
bracket assembly
3
2
STEP 1: Assemble spacer washers onto pivot pin.
pivot pin
T
5
4
6P
Item Part # Description
1. 1121296 Flex Arm Assembly - Std.
1121298 Flex Arm Assembly - 7 1/4"
2. 1111027 Spiral Torsion Spring
3. 1702888 External Retaining Ring - 1 1/4"
4. 112141511SMARTwire™ - 6 Ga. Plug - 10' 9"
5. 1704751 Harness Lock Pin - 1/4" x 7/8"
6. 1702108 Wire Clip - 3/4" ID
7. 1121414 Bellow Plate - Square Holes
8. 1121413 Bellow Plate - Round Holes
P. 1700398 Self-Drilling Screw - 1/4" x 3/4"
F. 1701455 Carriage Bolt - 5/16" x 2 1/2"
O. 1700403 Self-Tapping Screw - 1/4" x 3/4"
T. 1700408 Hex Nut - 1/4"
W. 1704931 Flanged Nylon Lock Nut - 5/16"
BB. 1700436 Lock Washer - 1/4"
CC. 1700427 Flat Washer - 1/4"
GG. 1702890 Flat Washer - 1 1/4"
HH. 1118318 Spacer Washer - 1/4" x 1.28"
O
7
W
F
8
flex arm joint w/bellow
lower flex arm
assembly
NOTE: Motor assembly on upper ex arm must face toward
trailer as shown.
upper flex
arm w/motor
W
F
bellow plate
w/square holes
STEP 2: Align holes in bellow and bellow plates with holes in
lower ex arm assembly as shown. Fasten with 5/16"
x 2 1/2" carriage bolts and lock nuts.
bellow plate
w/round holes
NOTE: Do not remove cable tie
from front ex arm and motor
assembly until installation is
complete. See step 4.
WARNING
Do not stand or climb on flex arm. Standing or climb-
ing on flex arm could result in fall/impact causing
serious injury or death.
!
BB
CC
GG
HH
HH

P/N 1121522 Rev. F
4
Front Flex Arm & Motor Installation - continued
STEP 7: Align adapter plug with 1 1/2" hole. Using plug as
guide, mark and drill two 7/32" holes as shown.
STEP 6: Measure 11" horizontally from center line of trailer and
1" down from lower edge of pivot bracket. Mark and
drill 1 1/2" hole through trailer skin.
drill 1 1/2" hole
pivot bracket
catwalk drill two
7/32" holes
pivot bracket
STEP 8: Fasten adapter plug to front of trailer with screws
E
, at washers Z, lock washers Y and nuts Q.
smartwire™ plug
NOTE: Wire lengths are predetermined. Before installing
SMARTwire™ components, review and conrm wire routing so
wires will reach components with ample room for connection.
Z
Y
Q
E
STEP 5: Choose appropriate pilot hole on pivot bracket to route
6-ga. wire from ex arm through trailer skin. Fasten
wire clip to pilot hole with 1/4" x 3/4" self-drilling screw.
NOTE: Fasten wire clip to pilot hole on opposite side of pivot
bracket from ex arm to prevent wire from being pinched
during operation.
P
wire clip
pilot
hole
flex arm
pivot bracket
STEP 4: Secure with 1 1/4" at washer and retaining ring.
retaining ring
f
STEP 3: Assemble spiral torsion springs and lower ex arm
onto pivot pin. Hook springs over 3/8" x 3 1/2" cap
screw and spacer tube.
spiral torsion springs
lower flex arm
STEP 9: Remove cable tie from front arm/motor assembly
before operating system.

P/N 1121522 Rev. F
5
Roll Tube Extension Installation
NOTE: To prevent rust, paint all exposed metal, such as weld
seams and/or metal exposed by grinding or cutting, with
corrosion-resistant paint.
STEP 1: Slide roll tube/roll tube extension weldment back into
position and align upper ex arm on front of trailer.
Install motor, positioning motor as shown below. Make
sure torsion springs load when tarp opens.
face panel
pivot bracket
WARNING
!
Flex arms are under tension while torsion springs
are engaged. Use caution while assembling and
disassembling arms. Failure to read and follow
instructions could result in serious injury or death.
NOTE: Verify again that ex arm is on a vertical plane
and parallel to face panel before proceeding. Make sure
all fasteners holding motor to upper ex arm bracket are
tightened securely.
STEP 2: Refasten and secure roll tube to electric motor shaft
with screw
O
and nut
X
. Install bearing spacers, radial
ball bearings and bearing mount retainer and secure
with nuts
S
.
roll tube
electric motor
bearing
mount
retainer
radial
ball
bearing
bearing
spacer
O
S
X
Item Part # Description
1. 1121296 Flex Arm Assembly w/Motor - Std.
1121298 Flex Arm Assembly w/Motor - 7 1/4"
2. 1120680 Motor Mount Bearing Spacer
3. 1704736 Radial Ball Bearing - 1/4" x 3/4"
4. 1128243 Motor Mount Bearing Retainer
5. 1120679 Motor Spacer
7. 1120697 Roll Tube Extension w/Drive Shaft - 34.43"
1120698 Roll Tube Extension w/Drive Shaft - 45.37"
1120699 Roll Tube Extension w/Drive Shaft - 74.87"
8. 1704982 4500 Series Motor Cover - Black
K. 1704057 Cap Screw - 3/8" x 2"
N. 1704367 Hex Flange Cap Screw - #10 x 3/4"
U. 1701543 Nylon Lock Nut - 1/4"
AA. 1701580 Nylon Lock Nut - 3/8"
4
5
3
U
K
2
1
7
N
8
AA

P/N 1121522 Rev. F
6
Roll Tube Extension Installation - continued
STEP 4: Reverse step 2 to unfasten and remove motor from
roll tube extension. Remove roll tube extension from
roll tube. Cut roll tube at marked location.
vertical plane
flex
arm
roll tube
roll tube
extension
cut here
face panel
90°
roll tube extension
w/drive shaft
roll tube
STEP 5: Insert swaged end of roll tube extension w/drive shaft
into roll tube. Align extension straight with roll tube
and weld all around. Grind smooth.
weld &
grind
smooth
roll tube
extension
w/drive shaft
NOTE: Pull roll tube away from tarp and trailer before welding
to protect from weld spatter. Align roll tube extension straight
with roll tube before welding so tarp system will roll smoothly.
STEP 3: Hold ex arm with motor and roll tube extension in
vertical plane to trailer and 90° to roll tube. Mark roll
tube at location to be cut.
NOTE: Requires two people for safe installation.
CAUTION
On certain trailers, clearance lights might be in
way of roll tube and can be damaged if caution is
not taken. In some instances, a ‘de flector’ might
have to be installed to prevent roll tube from causing
damage to lights.
!
STEP 7: Adjust rear roll tube extension to align ex arm on
vertical plane parallel to face panel. Do not drill holes
and/or fasten until tarp and roll tube are in desired
position.
STEP 8: Re-fasten tarp to roll tube with existing U-clamps and
screws. Tighten all fasteners securely. Tighten front
and rear ex arm connections.
STEP 6: Fasten motor cover onto motor with screws C.
motor
cover
motor
C

P/N 1121522 Rev. F
7
Stretch Cord Return
tarp
protective cover
belled pipe straight pipe 
end plug
straight pipe
belled pipe
stretch cord
tie knot
7/16"
end plug
mark location
roll tube
knot in
stretch cord
tie knot
3
1
4
2
STEP 3: Insert straight stretch cord return pipe into belled
stretch cord return pipe. Insert end plug into straight
stretch cord return pipe.
STEP 6: Mark location about 7/16" from edge of end plug.
Secure end plug to roll tube with self-drilling scre w B.
STEP 4: Insert stretch cord through end plug and roll return
pipes. Slide at washer EE over stretch cord and tie
knot in cord.
STEP 5: At rear of box, insert stretch cord return assembly
into roll tube. Lightly tap end plug into roll tube.
STEP 7: Drill 11/32" hole through latchplate, 1 1/2" from edge
of tarp. Insert eyebolt P through hole and secure with
nut T and lock nut V.
STEP 9: Tie knot in cord at
end plug. Slide pro-
tective cover over
stretch cord.
STEP 10: Thread stretch cord through eyebolt, applying enough
tension to almost lift roll tube. Tie knot.
tarp
1 1/2"
latchplate
drill
11/32"
hole
roll return assembly
end plug
roll tube
tarp
Item Part # Description
1. 1111067 Stretch Cord Return Tube Set
2. 1114360 Stretch Cord Return Cord - 11 1/2’
3. 1100138 Nylon End Plug
4. 1107680 Protective Stretch Cord Cover
B. 1704743 Self-Drilling Screw - #10 x 1/2"
F. 1700398 Self-Drilling Screw - 1/4" x 3/4"
P. 1700717 Eyebolt - 5/16" x 7/8" Thread
T. 1700411 Hex Nut - 5/16"
V. 1700419 Nylon Lock Nut - 5/16"
EE. 1703373 Flat Washer - 1/2"
T
V
P
STEP 8: With tarp closed and hanging
over edge of box, pull stretch
cord to remove all slack in
stretch cord return assembly.
STEP 1: Align roll tube to extend 1" past rear of tarp.
STEP 2: Center rst U-clamp on rear tarp strap, positioning
screw Fon crease at bottom of tarp pocket. Fasten
U-clamp with screw F.
1"
rear
of
box
u-clamp
5" pocket on tarp
1"
rear
tarp
strap
B
T
P
V
F
B
eyebolt
EE
EE

P/N 1121522 Rev. F
8
Shur-Return™
male end
female end
rear of tarp
u-clamp
expanded spring
untie knot
compressed spring
connector
seam
groove
1
2
3
4
5
STEP 1: Align grooves in male and female UPS-able Shur-
Return™ ends, insert female end into connector sleeve
and align set screws
A
opposite seam and tighten.
STEP 2: Cautiously untie knot and slowly allow spring to
expand to full length of UPS-able Shur-Return™.
STEP 3: Remove all 1/4" x 3/4" screws on U-clamps from rear
11' of tarp, then replace with screws D.
STEP 5: Tap end plug into roll tube and mark location 7/16"
from edge of end plug. Secure end plug to roll tube
with screw B.
STEP 6: Drill 11/32" hole into
latchplate 1 1/2" past end
of tarp. Insert eyebolt P
through hole and secure
with nut T and nut V.
STEP 7: Insert Shur-Return™ rope
through eyebolt, remove
all slack from rope and tie
knot.
NOTE: Follow steps 1 and 2 on page 7 before proceeding.
Steps 1 and 2 on this page are for UPS-able Shur-Return™
only.
NOTE: Spring is compressed. Use caution when untying knot.
NOTE: Do not
overtighten
set screws.
end plug
shur-return™
rope
roll tube
end plug
roll tube
7/16"
1 1/2"
tie
knot
eyebolt
rope
NOTE: Failure to replace screws
could result in Shur-Return™ failure.
TIP: Do not cut off
excess rope until sure
tarp will open completely.
drill
11/32"
hole
Item Part # Description
1. 1100138 Nylon End Plug
2. 1107879 Connector Sleeve
3. 1100826 Shur-Return™ Rope
4. 1100827 Spring Retainer Plug
5. 1100832 Shur-Return™ Assembly
(Spring - Rope - Slide)
A. 1701423 Set Screw - #10 x 3/16"
B. 1704743 Self-Tapping Screw - #10 x 1/2"
D. 1700736 Self-Tapping Screw - 1/4" x 1/2"
F. 1700398 Self-Drilling Screw - 1/4" x 3/4"
P. 1700717 Eyebolt Anchor - 5/16" x 7/8"
T. 1700411 Hex Nut - 5/16"
V. 1700419 Nylon Lock Nut - 5/16"
A
B
STEP 4: Insert Shur-Return™ into roll tube at rear of box, with
rope at open end of roll tube. Thread rope through
nylon end plug.
D
B
P
T
V
A
P
T
V
D

P/N 1121522 Rev. F
9
Rear Cable Return
STEP 1: Mark point on center line of face panel 3 1/8" above
upper edge of top rail.
1
2
3
17
5
67
8
9
10
11
12
13
14
7
8
STEP 8: Slide cable return loop and retaining collars over roll
tube. Fasten collars to roll tube with screws J.
STEP 4: Align cable return parallel with top rail on box.
STEP 5: Mark mounting holes and repeat steps 2 and 3.
STEP 6: Release tarp from latchplate and let hang over side
of trailer.
3 1/8"
crank assembly
roll tube
cable
return
loop
roll tube
TIPS - Install spacer, such as S/40 PVC pipe, to align cable
with pulleys and/or separate cable loop from weld. Adjust
cable to prevent rubbing on objects and fraying. Remove
weld spatter or debris from roll tube. Replace cable assembly
every two years. Roll tube must extend at least 4" past front
of trailer - purchase 4' roll tube P/N 1111719, if required.
7
10
4
18
8
15
16
13
STEP 7: Remove crank assembly from roll tube.
STEP 2: Center punch and drill 13/32" hole at mark.
STEP 3: Align center mounting hole on return to drilled hole in cap
and fasten with screw
M
, lock washer
CC
and nut
W
.
Item Part # Description
1113025 Rear Cable Return Kit - Heavy Duty
1120650 Front Cable Return Kit - Heavy Duty -
Reverse Roll
1116117 Cable Guide Kit
1. 1114728 Universal Cable Return Housing
2. 1115014 Spacer Washer - 1 5/8"
3. 1115206 Velcro® Brand Hook
4. 1702655 Machine Screw - #10 x 1 1/4"
5. 1114582 Cable Return Strap
6. 1114691 Front Retainer Plate
7. 1703006 Pulley - 1"
8. 1111056 Plastic Spacer - 3/8"
9. 1110913 Rear Retainer Plate
10. 1702654 Machine Screw - #10 x 1"
11. 1702656 Machine Screw - #10 x 1 1/2"
12. 1702672 Cap Screw - 1/4" x 2 1/4"
13. 1702653 Machine Screw Nut - #10
14. 1701543 Nylon Lock Nut - 1/4"
15. 1112997 Rope Block Retainer Plate
16. 1701134 Oval Sleeve - 3/32" Cable
17. 1702896 Extension Spring
18. 1111054 Flat Washer - #10
M. 1700400 Self-Tapping Screw - 3/8" x 1"
W. 1700407 Hex Nut - 3/8"
CC. 1700434 Lock Washer - 3/8"
M
W
retaining
collars
J
CC

P/N 1121522 Rev. F
10
Value Series Stretch Cord Return
STEP 3: Mount shock cord tie-down strap 10’ back from rear
edge of latchplate. Drill 5/16" hole and fasten with
screws M.
STEP 2: Using eye bracket as guide, mark and drill 5/16" hole
in trailer. Fasten bracket to trailer with screws M.
STEP 1: Open tarp against tarp stops. At rear of box, locate
eye bracket in conguration shown.
10’
latchplate
tie-down
strap
eye bracket
shock
cord
STEP 4: Lead shock cord through eye bracket, then through
grommet on tie-down strap. Tie knot in shock cord at
tie-down strap to secure. Trim end of shock cord and
wrap with tape to prevent fraying.eye bracket
latchplate
tie-down strap
Item Part # Description
1. 1703445 Shock Cord Eye Bracket
2. 1114948 Shock Cord Tie-Down Strap
3. 1100169 Shock Cord - 138"
4. 1114947 Roll Tube Eye
5. 1704352 Retaining Collar
J. 1704353 Self-Drilling Screw - 1/4" x 1"
M. 1700400 Self-Tapping Screw - 3/8" x 1"
2
1
3
STEP 5: Allow shock cords to hang down. Slide roll tube eye
onto rear end of roll tube and align eye about 1" from
shock cord, toward outside of trailer. Space retain-
ing rings about 1/8" from each side of roll tube eye.
Tighten screws Jto secure retaining rings.
roll tube eye
roll tube
shock cord
retaining ring
STEP 6: Roll tarp closed tight under latchplate and pull shock
cord through roll tube eye to create tension. Tie per-
manent knot in shock cord at rear of roll tube.
STEP 7: Roll tarp open and closed to make sure roll tube
returns correctly. Adjust tension in shock cord as
needed. Trim end of shock cord and wrap with tape
to prevent fraying.
roll tube
tape
shock cord
roll tube eye
retaining
collar
eye bracket
M
M
M
M
J
J
5
4

P/N 1121522 Rev. F
11
Rocker Switch - Cab Wiring
STEP 2: Mount solenoid in suitable location - a ventilated area
near battery is ideal. Determine best route for wire,
usually along frame with existing wire harness. Run
6-ga. wire from conductor plug to solenoid and from
power supply to solenoid as shown in diagram. Run
14-ga. wire from solenoid to switch.
STEP 3: Locate rocker switch in convenient operating location.
Switch can be mounted in cab, on dash panel, on driver
side door jamb or in convenient location outside cab.
connect wires to
switch as shown
set screw
insert
conductor plug
positive wire -
colored stripe
on top
brass contact
wire
STEP 4: Unfasten and remove insert from conductor plug. Feed
6-ga. wire through plug and into brass contacts on
insert. Tighten set screws to secure wires. Replace
insert into conductor plug and secure screw.
negative
(ground)
wire
STEP 1: Mount circuit breaker as close as possible to battery
or power supply.
battery
rocker
switch
relay solenoid
circuit
breaker
conductor
plug
jumper wire
provided
Item Part # Description
1. 1703661 Rocker Switch Mounting Bracket
2. 1116020 Rocker Switch
3. 1703845 Motor-Reversing Solenoid
4. 1704751 Harness Lock Pin - 1/4" x 7/8"
5. 1115385 Heavy-Duty Dual-Conductor Plug
6. 1120670 SMARTwire™ Dual-Conductor Socket
7. 1704354 40-Amp Modied-Reset Circuit Breaker
8. 1703896 Solenoid Cover
9. 1703659 Push-On Terminal - 14 Ga. 1/4”
10. 1704153 Ring Terminal - 14 Ga. x 1/4” Stud
11. 1703244 Ring Terminal - 6 Ga. x 3/8” Stud
12. 1703245 Ring Terminal - 6 Ga. x #10 Stud
13. 1702707 Ring Terminal - 6 Ga. 1/4 Stud
H. 1704905 Flanged Cap Screw - #10 x 1"
K. 1701045 Cap Screw - 5/16" x 3/4"
R. 1808844 Nylon Lock Nut - #10
U. 1704946 Flanged Top Lock Nut - 5/16"
Z. 1700427 Flat Washer - 1/4"
electric
motor
3
2
7
1
5
6
U
K
mount circuit breaker as close
to power supply as possible
H
8
4
Z
R
WARNING
!
When transporting trailer, wiring from in-
cab rocker switch must be connected to
4500 HD system on trailer. If motor is not
connected to power while in transit, tarp
may unwind and blow off.
NOTE: Cut wires to length and strip only enough wire
insulation to install ring terminals. Insert bare wire into
ring terminals and crimp securely.
strip wire
insulation
ring terminal crimp securely
9
11
10
13
12

P/N 1121522 Rev. F
12
Rocker Switch - Trailer Mounting & Wiring
NOTE: Release switch at end of cycle or modied-reset
circuit breaker will trip. After breaker resets, switch will
activate motor again. To reduce unnecessary strain on tarp
components, release switch at end of each cycle.
CAUTION
Check all hardware for complete assembly before
operating. Inspect system at this time and adjust
as required.
!
OPERATION:
A) Check motor direction by activating switch to Open. If switch
is running system backwards, change wire leads on dual con-
ductor plug to opposite connections.
B) Close tarp: Push switch to Close and hold. Observe tarp and
release switch when tarp is fully closed.
C) Open tarp: Push switch to Open and hold. Observe tarp and
release switch when tarp is fully opened.
CAUTION
Do not cut SMART-
wire™. Bind excess
wire with cable ties.
!
STEP 1: Connect SMARTwire™ from electric motor to SMART-
wire™ from dual conductor and secure connection with
lock pin. Secure all wires to trailer with cable clips and
screws. If needed, use cable ties.
smartwire™
from motor
NOTE: Coat each connection with dielectric grease (P/N
1704378) to prevent corrosion.
STEP 2: Align socket over 2" hole. Using holes in anges on
socket as guide, mark and drill two 5/16" holes.
drill two
5/16" holes
7-pole
conductor
drill 2" hole
STEP 1: Locate dual-pole conductor socket near 7-pole con-
ductor socket as shown. Determine location and drill
2" hole through trailer skin.
STEP 3: Fasten conductor socket to trailer with screws K,
washers Z and nuts U.
smartwire™
smartwire™ from
dual conductor
NOTE: Wire lengths are predetermined. Before installing
SMARTwire™ components, review and conrm wire routing so
wires will reach components with ample room for connection.
WIRING SCHEMATIC
DUAL CONDUCTOR
K
U
front of trailer
Z

P/N 1121522 Rev. F
13
STEP 2: Unfasten and remove insert from conductor plug.
Feed 6-ga. wire through plug and into brass contacts
on insert. Tighten set screws to secure wires. Replace
insert into conductor plug and secure screw.
Wireless Receiver - Cab Wiring
set screw
insert
conductor plug
positive wire - colored
stripe on top
brass contact
wire
negative
(ground) wire
STEP 1: Mount circuit breaker as close as possible to battery
or power supply.
circuit breaker
battery
conductor plug
electric
motor
mount circuit breaker as close
to power supply as possible
Item Part # Description
1. 1115385 Heavy-Duty Dual-Conductor Plug
2. 1120670 SMARTwire™ Dual-Conductor Socket
3. 1109015 Harness Lock Pin - 1/4" x 7/8"
4. 1702108 Wire Clip - 3/4"
5. 1704354 40-Amp Modied-Reset Circuit Breaker
6. Shur-Co® Wireless Receiver
7. 1703244 Ring Terminal - 6 Ga. x 3/8" Stud
G. 1704338 Self-Tapping Screw - 1/4" x 1"
K. 1701045 Cap Screw - 5/16" x 3/4"
L. 1702926 Cap Screw - 5/16" x 7/8"
U. 1704946 Flanged Top Lock Nut - 5/16"
V. 1700419 Lock Nut - 5/16"
Z. 1700427 Flat Washer - 1/4"
AA. 1700428 Flat Washer - 5/16"
6
3
1
U
2
5
V
L
4
G
KZ
NOTE: Cut wires to length and strip
only enough wire insulation to install
ring terminals. Insert bare wire into ring
terminals and crimp securely.
strip wire
insulation
ring
terminal crimp securely
NOTE: Only one electric tarp
system can be hooked up at a time.
7
AA

P/N 1121522 Rev. F
14
Wireless Receiver - Trailer Mounting & Wiring
front of trailer
electric
motor
STEP 3: Fasten conductor socket to trailer with screws K,
washers Z and nuts U.
smart wire
STEP 2: Align socket over 2" hole. Using holes in anges on
socket as guide, mark and drill two 5/16" holes.
drill two
5/16" holes
7-pole
conductor
drill 2" hole
DUAL-CONDUCTOR SOCKET
NOTE: Wire lengths are predetermined. Before installing SMARTwire™ components, review and conrm wire routing so wires will
reach components with ample room for connection.
STEP 1: Locate dual-pole conductor socket near 7-pole con-
ductor socket as shown. Determine location and drill
2" hole through trailer skin.
CAUTION
Do not fasten SMARTwire™ components to trailer
through hopper walls.
!
K
U
Z
smartwire™
decal
p/n1705546
encoder wire
for smart2™
& smart3™
systems

P/N 1121522 Rev. F
15
CAUTION
Check all hardware for complete assembly before
operating. Inspect system at this time and adjust
as required.
!
NOTE: Receiver may be pressure washed, but keep nozzle
at least 3' from system while spraying.
STEP 1: Connect SMARTwire™ from wireless receiver to
SMARTwire™ from electric motor. Connect SMART-
wire™ from wireless receiver to SMARTwire™ from
conductor socket. Secure connections with lock pins.
Secure wires to trailer with cable clips and screws. If
needed, use cable ties.
NOTE: Coat each connection with dielectric grease (P/N
1704378) to prevent corrosion.
smartwire™
from motor
lock pin
lock pin
smartwire™
from wireless
receiver
smartwire™
from conductor
socket
Wireless Receiver - Trailer Mounting & Wiring
STEP 2: Align holes in wireless receiver over 2" hole in trailer
as shown below. Using holes on anges on receiver
as guide, mark and drill four 5/16" holes as shown.
STEP 1: In order to clear travel area of front arm, locate Shur-
Co® wireless receiver as low as possible on front of
trailer. Determine location and drill 2" hole through
trailer skin.
drill 2" hole
mark & drill
four 5/16" holes
align holes
in wireless
receiver with
hole in trailer
2" hole in trailer
STEP 3: Install grommet into 2" hole. Insert wire from wireless
receiver through grommet.
STEP 4: Align holes on wireless receiver with holes on trailer.
Fasten receiver to trailer with screws L, washers
AA and nuts V. Adhere warning decal P/N 1705546
above receiver in location shown.
wireless
receiver
wire from
wireless
receiver
grommet
2" hole
SHUR-CO®WIRELESS RECEIVER WIRING SCHEMATIC
L
V
STEP 2: Check motor direction by pressing either button. If
button is released and operation continues, system
is in Express Mode. To stop operation, press button
again. If switch is running system backwards, program
remote to wireless receiver and rewire as directed in
troubleshooting guide in remote instructions.
press c to
close tarp
press o to
open tarp
apply
warning decal
p/n1705546
encoder
wire
AA

P/N 1121522 Rev. F
16
Operation
press c to
close tarp
press o to
open tarp
NOTE: Tarp systems will operate in EXPRESS MODE when
using buttons on trailer-mounted control box, if encoder
wires are connected. For SMART2™ systems, travel stops
must also be set, otherwise you must press and hold
buttons. When in EXPRESS MODE, press and release
buttons to open and close tarp (operation will continue
until complete after releasing button). When in MANUAL
MODE, press and hold buttons (operation will stop if button
is released). See remote instruction manual for detailed
instructions on remote operation.
WARNING
Stay clear of roll tarp and arm(s) area of travel during
operation. Failure to do so could result in serious
injury or death.
!
NOTE: Tarp systems operate in EXPRESS MODE when
commanded to operate from buttons on trailer-mounted
control box. Closing remote lid or pressing select button will
not stop system in this case. Pressing OPEN or CLOSE
button on remote will stop system if in range.
NOTE: Tarp systems operate in EXPRESS MODE when
using buttons on trailer-mounted control box, if encoder
wires are connected. For SMART2™ systems, travel stops
must also be set. Otherwise you must press and hold
buttons (see remote instructions for SMART2™ systems).
NOTICE
Decal shown above must be placed above wire-
less receiver on front of box.
!
NOTE: 4500 Series HD trailer-mounted control boxes now
operate in EXPRESS MODE. Pressing Oor Cbutton
on control box initiates express open or close operation.
After that, pressing either button will stop tarp operation. If
neither button is pressed, operation will automatically stop
at end of travel. On SMART2™ systems, if travel stops are
not set, trailer-mounted control box operates in MANUAL
(momentary) MODE. Remotes for both systems are shipped
with tarp channel set to EXPRESS MODE and can be
congured as desired.

P/N 1121522 Rev. F
17
Electric Motor Replacement
lock washer
ring terminal
electric motor terminal
hex nut
rubber boot
motor
cover
CAUTION
Check all hardware for complete assembly be-
fore operating. Inspect system at this time and
adjust as required.
!
NOTE: Leave roll tube fastened to motor bracket.
STEP 1: Disconnect electric power to trailer. Unfasten and
remove motor cover. Unfasten screw O and nut X
holding motor shaft to roll tube/front arm assembly.
STEP 2: Disconnect electric wires from motor terminals.
STEP 3: Unfasten and remove only washers BB and nuts T
holding motor to motor bracket/front arm assembly,
leaving motor mount bearing retainers in place. Re-
move existing motor.
STEP 3: Fasten motor shaft to roll tube with screw O and nut
X. Replace motor cover and fasten to motor with
screws C. Reconnect electric power.
motor
shaft
O
STEP 2: Connect electric wires to motor terminals.
lock washer
ring terminal
electric motor terminal
hex nut
rubber boot
motor
cover
C
motor
shaft
existing
motor
new
motor
motor bracket/
front arm
assembly
motor bracket/
front arm
assembly
motor
bracket
roll tube O
C
X
X
T
T
STEP 1: Install new motor. Fasten motor to motor bracket with
washers BB and nuts T.
REMOVE EXISTING MOTOR INSTALL NEW MOTOR
BB
BB