Shurco 4500 HD Series User manual

Aluminum System - Articulating Rear
Arm 0" to 12" Hinge Depth
Live-Bottom Trailer
standard roll
P/N 1124662 Rev. F

Shur-Co®, LLC Terms & Conditions
SHIPPING. Orders are shipped F.O.B. from the Shur-Co®, LLC sites listed be-
low. No full freight is allowed 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®, LLC SERVICE AND DISTRIBUTION CENTERS
Corporate HQ and Outlet Store
SHUR-CO® of SOUTH DAKOTA
2309 Shur-Lok St., PO Box 713, Yankton, SD 57078
Ph 800.474.8756 | Fax [phone]
SHUR-CO® of FLORIDA
3353 SE Gran Park Way, Stuart, FL 34997
Ph 800.327.8287 | Fax [phone]
SHUR-CO® of IDAHO
610 N. 16th Ave., Caldwell, ID 83607
Ph 866.356.0246 | 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]
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 MICHIGAN
5100 Lakeshore Dr., Lexington, MI 48450
Ph 800.327.8287 | Fax [phone]
SHUR-CO® of NORTH DAKOTA
1746 4th Ave. NW, West Fargo, ND 58078
Ph 877.868.4488 | Fax [phone]
SHUR-CO® of OHIO
4676 Lynn Rd.
Rootstown, 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 information, log on to our website:
www.shurco.com
P/N 1124662 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, 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.
P/N 1124662 Rev. F
Hardware Identication.......................................................................1
Front Pivot Bracket Installation...........................................................2
Front Flex Arm & Electric Motor Installation ....................................3-4
Rear Mounting Beam & Spring Pivot Installation................................5
Rear Hi-Lift Flex Arm Installation........................................................6
Front Drive Shaft - 3" Roll Tube Installation ....................................7-8
Manual Crank Adapter Installation......................................................9
Roll Tube Extension Installation - 2" Roll Tube Option ................10-12
Rocker Switch - Cab Wiring..............................................................13
Rocker Switch - Trailer Mounting & Wiring .......................................14
Wireless Receiver - Cab Wiring........................................................15
Wireless Receiver - Trailer Mounting & Wiring ............................16-17
Operation..........................................................................................18
Convert to Manual Power.................................................................19
Electric Motor Replacement .............................................................20
Replacement Parts......................................................................21-23
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. 7/32" Drill Bit
13. 5/16" Drill Bit (for 3/8" self-tapping screws)
14. 11/32" Drill Bit
15. 13/32" Drill Bit
16. 3/8" Drill
17. 1 1/8" Hole Saw
18. 1 1/2" Hole Saw
19. 2" Hole Saw (if bracket for conductor socket is not used)
20. Standard/Flathead Screwdriver
21. #2 Phillips Screwdriver
22. Utility Knife
23. Ratchet
24. Hack Saw (metal cutter)
25. Pliers
26. Snap-Ring Pliers
27. Wire Cutters
28. Grinder
29. Tape Measure
!
TOOLS REQUIRED
RUST PREVENTION
SAFETY
MESSAGE TO OWNERS TABLE OF CONTENTS
4500 Series HD - 43" Hinge Articulating Rear Arm 0" to 12" Hinge Depth
Live-Bottom Trailer
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 1124662 Rev. F
Hardware Identication
1
1701455 Carriage Bolt - 5/16" x 2 1/2"
1701045 Cap Screw - 5/16" x 3/4"
1201022 Cap Screw - 5/16" x 3 1/2"
1700400 Self-Tapping Screw - 3/8" x 1"
1705198 Self-Drilling Screw - 1/4" x 1"
1704338 Self-Tapping Screw - 1/4" x 1"
1702926 Cap Screw - 5/16" x 7/8"
A
B
D
E
F
G
H
J
K
M
N
1704905 Hex Flanged Cap Screw - #10
1700398 Self-Drilling Screw - 1/4" x 3/4"
1704367 Cap Screw - #10 x 3/4"
P
C
1700403 Self-Tapping Screw - 1/4" x 3/4"
L
1704943 Shoulder Bolt - 3/8" x 2" - 5/16" x 1/2" Thd.
1704237 Carriage Bolt - 5/16" x 1"
1701061 Cap Screw - 3/8" x 1"
Inspect all parts in 4500 Series HD
electric kit upon arrival.
1700429 Flat Washer - 3/8"
1700419 Nylon Lock Nut - 5/16"
1700407 Hex Nut - 3/8"
1700434 Lock Washer - 3/8"
1702891 Cap Screw - 3/8" x 1 1/4"
1118318 Spacer Washer - 1/4" x 1.81"
1702890 Flat Washer - 1-1/4"
1700427 Flat Washer - 1/4"
1700428 Flat Washer - 5/16"
1701580 Nylon Lock Nut - 3/8"
Q
R
S
T
U
V
Z
X
Y
AA
BB
CC
1120291 Pivot Bracket Washer
1706103 Rivet - 3/16”
1808844 Nylon Lock Nut - #10
1700436 Lock Washer - 1/4"
DD
EE
FF
1704931 Flanged Nylon Lock Nut - 5/16"
W
1702573 Cap Screw - 3/8" x 2 1/2" GG
1700371 Cap Screw - 3/8" x 3"
1700408 Hex Nut - 1/4"
1700411 Hex Nut - 5/16"
1701543 Nylon Lock Nut - 1/4"
1704297 Nylon Lock Nut - 5/16" - ZP
1701062 Hex Jam Nut - 3/8"
1701283 Flanged Top Lock Nut - 3/8"
1702668 Top Lock Nut - 3/8"
RR
SS
PP
NN
LL
KK
JJ
HH
1704264 Cap Screw - 3/8" x 2"
1704946 Flanged Top Lock Nut - 5/16"
QQ

P/N 1124662 Rev. F
2
rivets off
center
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.
Q
Q
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. 1121578 Vertical Pivot Mount Bracket - 9 1/4" Standoff
Q. 1702891 Cap Screw - 3/8" x 1 1/4"
CC. 1700407 Hex Nut - 3/8"
NN. 1700434 Lock Washer - 3/8"
PP. 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
1
STEP 3: Remove rivets and mount brackets into rivet holes. If not
possible, drill 13/32" holes in trailer. Fasten with screws
Q
, at washers
PP
, lock washers
NN
and nuts
CC
.
c
l
c
l
c
l
2
41"
NOTE: Use pivot bracket washers only when horizontal
corrugation on trailer skin prevents bracket from contacting skin.
STEP 4: 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 Q, at washers PP , lock
washers
NN
, pivot bracket washers
RR
and nuts
CC
.
Locate pivot bracket washers between pivot bracket
and trailer skin as shown.
pivot bracket
corrugated trailer skin locate pivot bracket
washers between pivot
bracket & trailer skin
HORIZONTALLY CORRUGATED TRAILERS
FRONT OF TRAILER
Front Pivot Bracket Installation
Q
Q
CC
CC
RR
RR
PP
PP
NN
NN
QCC
RR
PP NN
CC
CC
PP
PP
PP
PP
NN
NN

P/N 1124662 Rev. F
3
Front Flex Arm & Electric Motor Installation
1
pivot mount
bracket assembly
3
2
STEP 1: Assemble spacer washers QQ onto pivot pin.
pivot pin
V
5
4
6D
Item Part # Description
1. 1121296 Flex Arm Assembly w/Motor - Std.
1121298 Flex Arm Assembly w/Motor - 7 1/4"
2. 1111027 Spiral Torsion Spring
3. 1702888 External Retaining Ring - 1 1/4"
4. 1120816 SMARTwire™ - 6 Ga. Plug - 9' 9"
w/Encoder Wire
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
9. 1704893 Cap Plug w/Hole
C. 1700403 Self-Tapping Screw - 1/4" x 3/4"
D. 1700398 Self-Drilling Screw - 1/4" x 3/4"
K. 1701455 Carriage Bolt - 5/16" x 2 1/2"
V. 1700408 Hex Nut - 1/4"
Z. 1704931 Flanged Nylon Lock Nut - 5/16"
HH. 1700436 Lock Washer - 1/4"
JJ. 1700427 Flat Washer - 1/4"
KK. 1702890 Flat Washer - 1 1/4"
QQ. 1118318 Spacer Washer - 1/4" x 1.28"
C
7
Z
K
8
9
flex arm joint
lower flex arm
NOTE: Motor assembly on upper ex arm must face toward
trailer as shown.
flex arm
assembly
w/motor
STEP 2: Align holes in bellow, end tting and bellow plates with
holes in lower ex arm assembly as shown. Fasten
with carriage bolts K and lock nuts Z.
bellow plate
w/square holes
bellow plate
w/round holes
K
Z
NOTE: Do not remove cable tie
from front ex arm and motor
assembly until installation is
complete. See step 6.
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.
!
HH
KK
JJ
QQ
QQ

P/N 1124662 Rev. F
4
Front Flex Arm & Motor Installation - continued
NOTE: Fasten wire clip to pilot hole on opposite side of pivot
bracket from ex arm to prevent wire from being pinched
during operation.
D
wire clip
pilot
hole
flex arm
pivot
bracket
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 screw D.
STEP 4: Secure with washer KK and retaining ring.
retaining ring
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 6: Remove cable tie from front arm/motor assembly
before operating system.
KK

P/N 1124662 Rev. F
5
Rear Mounting Beam & Spring Pivot Installation
STEP 2: Hold beam in place and use as guide to mark and drill
5/16" holes into rear door. Fasten with screws
N
, lock
washers
NN
and nuts
CC
.
STEP 1: Center beam on rear of trailer, positioning beam so
spring pivot shaft is located as shown.
NOTE: If fastening through tubing, alternate fasteners may
be needed. Add bracing/reinforcement if door skin is too
weak to support beam and spring pressure.
STEP 3: Fasten spring pivot assembly to beam. On front
of beam, measure and mark 11" from center of beam
toward curb side of trailer. Center pivot backer plate
on mark and use as guide to locate and drill 3/8"
holes. Place plate on backside of beam and repeat
process to ensure alignment of holes on backside of
beam with holes on front of beam.
STEP 4: Place spring pivot assembly and backer plate on either
side of beam as shown and fasten with screws T and
lock nuts EE .
from top of side
rails or extensions
22 3/16" ref.
30"
11"
N
beam
drill
5/16"
holes
rear of trailer
11"
pivot
backer
plate
beam
drill 3/8" holes
on front & back
center
of beam
spring pivot
assembly
backer
plate
beam T
EE
CC
NN

P/N 1124662 Rev. F
6
Rear Hi-Lift Flex Arm Installation
STEP 2: To correctly position spring and spring shaft, make
sure front leg of spring is positioned as shown below.
Then turn shaft clockwise until shaft catches in hook
at rear of spring.
STEP 3: Align rear ex arm with spring shaft as show below
and slide pivot connector onto shaft. Align set screw
in pivot connector with hole in shaft and tighten until
screw bottoms out in hole. Tighten other set screw,
then tighten jam nuts to lock set screws into shaft.
NOTE: Make sure arm upper arm is oriented as shown with
lower arm, or arm may be damaged in operation.
STEP 4: With tarp hanging loosely in closed position, lift ex
arm up to roll tube and slide upper ex arm connector
onto roll tube. Adjust connector forward or backward
to align upper arm with lower arm on vertical plane.
To check alignment, measure distance between upper
and lower arms and rear door on trailer.
STEP 1: Assemble ex arm. Align ex hose connector on
upper ex arm assembly with lower ex arm as shown
and slide connector into ex arm. Fasten connector
to lower ex arm with screws
S
and lock nuts
EE
.
If ex arm comes pre-assembled, begin with step 2.
NOTE: For systems using 3" roll tube, wait until after manual
crank/spline adapter has been installed.
NOTE: Wait to do this step until after front arm has been
connected and both front and rear arms are correctly aligned.
flex hose
connector
upper flex arm
S
lower flex arm
turn spring
shaft clockwise
position front
leg as shown
hook at
rear of
spring spring
pivot
connector
on rear
flex arm
spring shaft
set screw
jam nut
roll tube
upper flex arm
connector
upper and lower
arms must be
aligned an equal
distance from
rear door
rear door
equal
distance
equal
distance
EE
STEP 5: With rear arm correctly aligned, fasten rear arm bear-
ing ring on rear arm assembly to roll tube. Drill 3/16"
holes and fasten bearing ring to roll tube with rivets
SS .
3" ROLL TUBE2" ROLL TUBE
align roll tube
so channel does
not interfere
w/screws
3" roll tube
rear arm
assembly
2" roll tube
SS

P/N 1124662 Rev. F
7
Item Part # Description
1. 1122264 Drive Shaft
2. 1118194 Cartridge Clamp
3. 1128243 Motor Mount Bearing Retainer
4. 1704736 Radial Ball Bearing - 1/4" x 3/4"
5. 1120680 Motor Mount Bearing Spacer
6. 1120679 Motor Spacer
F. 1705198 Pan Hd. Self-Drilling Screw - 1/4" x 1"
J. 1704237 Carriage Bolt - 5/16" x 1"
N. 1700400 Self-Tapping Screw - 3/8" x 1"
R. 1704264 Cap Screw - 3/8" x 2" - GR8
W. 1701543 Nylon Lock Nut - 1/4"
AA. 1704297 Nylon Lock Nut - 5/16"
EE. 1701580 Nylon Lock Nut - 3/8"
Front Drive Shaft - 3" Roll Tube Installation
STEP 3: Slide motor spacer over motor shaft. Slide drive
shaft over motor shaft. Fasten with screws
R
and
nuts
EE
. Finger tighten only.
motor
spacer
motor shaft
drive
shaft
roll tube
STEP 1: Loosely fasten cartridge clamp to drive shaft with
screw J and lock nut AA . Insert drive shaft into roll
tube. To secure drive shaft to roll tube, tighten nut
AA to 20-ft./lbs.
motor mount
assembly
STEP 2: Install three screws F through roll tube and ats on
drive shaft collar. Drill 5/16" hole between ats and
collar, then fasten screw N through roll tube and
collar.
drill
5/16"
hole
drive
shaft
collar
1/2"
align all
screws 1/2"
from edge of
roll tube
JFN
R
J
N
F
R
4
3
2
1
5
6
drive
shaft
cartridge
clamp
W
EE
AA
EE
AA

P/N 1124662 Rev. F
8
Front Drive Shaft - 3" Roll Tube Installation - continued
face panel
pivot bracket
motor
STEP 6: Align ex arm vertically with front of trailer and at 90°
angle to roll tube.
align flex arm
w/vertical
plane parallel
to face panel
roll tube
vertical plane
90°
STEP 5: Position motor as shown below. Make sure torsion
springs load when tarp opens.
STEP 4: Fasten drive shaft to electric motor shaft with screw
R
and nut
EE
. Install bearing spacers, radial ball bear-
ings and bearing mount retainer and secure with 1/4"
lock nuts
W
.
drive shaft
electric motor
bearing
mount
retainer
radial
ball bearing
bearing spacer
CAUTION
If clearance lights are in path of roll tube, install
de flector to prevent roll tube from damaging lights.
!
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: Make sure all fasteners holding motor to upper ex
arm bracket are tightened securely.
R
W
EE

P/N 1124662 Rev. F
Manual Crank Adapter Installation
9
2
1
3
Item Part # Description
1. 1121040 Roll Tube Cap - 3" Spline
2. 1121111 Manual Crank Spline - 3" Tube
3. 1121039 Cartridge - 3" Spline End
4. 1118194 Cartridge Clamp
F. 1705198 Self-Drilling Screw - 1/4" x 1"
J. 1704237 Carriage Bolt - 5/16" x 1"
R. 1704264 Cap Screw - 3/8" x 2"
AA. 1704297 Nylon Lock Nut - 5/16"
FF. 1702668 Top Lock Nut - 3/8"
3" roll tube
4
STEP 2: Insert cartridge assembly into roll tube. Position car-
tridge to extend 1 5/8" past end of roll tube. Tighten
nut to 20-ft./lbs.
STEP 3: Insert cap into roll tube/cartridge assembly. Fasten
three screws F through roll tube and ats on sides
of cap.
screws must
go through
flats on cap
STEP 4: Insert manual crank spline into roll tube assembly.
Secure with screw AA and nut FF .
1 5/8"
cartridge
tighten nut
cartridge
roll tube
clamp
roll tube/
cartridge
assembly
cap
manual crank spline
roll tube
assembly
R
F
J
STEP 1: Assemble cartridge, nut
AA
, clamp and carriage bolt
J
.
J
F
AA
FF
AA
FF
AA
STEP 5: When both front and rear ex arms are vertical, fasten
bearing ring in bearing mount bracket to roll tube with
two rivets SS .
roll tube
bearing mount
bracket
SS

P/N 1124662 Rev. F Roll Tube Extension Installation - 2" Roll Tube Option
10
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. 4500 Series HD Motor Cover - Black
A. 1704367 Hex Flange Cap Screw - #10 x 3/4"
R. 1704264 Cap Screw - 3/8" x 2" - Grade 8
W. 1701543 Nylon Lock Nut - 1/4"
EE. 1701580 Nylon Lock Nut - 3/8"
STEP 1: Adjust roll tube toward front or rear of trailer so rear
ex arm lies on vertical plane parallel to face panel
and perpendicular to roll tube extension. Mark roll
tube where roll tube extension ends.
align flex arm
with vertical
plane parallel
to face panel
face panel
roll tube
vertical plane
flex
arm
90°
STEP 2: Slide tarp back on roll tube.
roll tube
tarp
4
5
3
2
7
8
A
R
W
REAR OF TRAILER FRONT OF TRAILER
1
EE

P/N 1124662 Rev. F
11
Roll Tube Extension Installation - 2" Roll Tube Option - continued
STEP 5: Reverse step 3B to unfasten and remove motor from
roll tube extension. Remove roll tube extension from
roll tube. Cut roll tube at marked location.
STEP 4: Hold ex arm with motor and roll tube extension in
vertical plane to trailer and at 90° angle to roll tube.
Mark roll tube at location to be cut.
vertical plane
flex
arm
roll tube
roll tube
extension
cut here
face panel
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.
!
90°
STEP 3A: Slide motor spacer over motor shaft.
STEP 3B: Slide roll tube extension over motor shaft. Fasten with
screws R and lock nuts EE . Finger tighten only.
Fasten roll tube extension to motor mount bracket:
motor
spacer
motor shaft
roll tube
extension
motor shaft
roll tube extension
w/drive shaft
roll tube
STEP 6: Insert swaged end of roll tube extension with 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.
R
EE

P/N 1124662 Rev. F
12
STEP 10: 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 12: Re-fasten tarp to roll tube with existing U-clamps and
screws. Tighten all fasteners securely. Tighten front
and rear ex arm connections.
NOTE: Verify again that ex arm is on vertical plane parallel to
face panel before proceeding. Make sure all fasteners holding
motor to upper ex arm bracket are tightened securely.
STEP 8: Refasten and secure roll tube to electric motor shaft
with screw
R
and lock nut
EE
. Install bearing spacers,
radial ball bearings and bearing mount retainer and
secure with lock nuts
W
.
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: To prevent rust, paint all exposed metal, such as weld
seams and/or metal exposed by grinding or cutting, with
corrosion-resistant paint.
STEP 7: Slide roll tube/roll tube extension weldment back into
position and align upper ex arm on front of trailer. Fol-
low step 8 to install motor, positioning as shown below.
Make sure torsion springs load when tarp opens.
face panel
pivot bracket
roll tube
electric motor
bearing
mount
retainer
radial
ball
bearing
bearing
spacer
STEP 9: Fasten motor cover onto motor with screws A.
motor
cover
motor
W
R
A
Roll Tube Extension Installation - 2" Roll Tube Option - continued
EE
STEP 11: When both front and rear ex arms are vertical, fasten
two rivets SS into roll tube and roll tube cap.
roll tube
bearing mount bracket
roll tube cap
SS

P/N 1124662 Rev. F
13
Rocker Switch - Cab Wiring
electric
motor
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
B. 1704905 Hex Flanged Cap Screw - #10
G. 1701045 Cap Screw - 5/16" x 3/4"
U. 1808844 Nylon Lock Nut - #10
Y. 1704946 Flanged Top Lock Nut - 5/16"
JJ. 1700427 Flat Washer - 1/4"
3
2
4
7
1
5
6
Y
G
mount circuit breaker as close
to power supply as possible
STEP 2: Mount solenoid in suitable location - 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. Run 14-ga. wires
from solenoid to switch.
STEP 3: Locate rocker switch in convenient operating location.
Switch can be mounted in cab, on dash panel or on
driver side door jamb.
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
U
B
8
keyway facing up
close
open
NOTE: Only one electric tarp
system can be hooked up at a time.
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
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 cab-wired solenoid while
in transit, tarp may unwind and blow off.
10
12
13
11
9
JJ

P/N 1124662 Rev. F
14
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.
!
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 socket and secure connec-
tion 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
seven-pole
conductor
drill 2" hole
STEP 1: Locate dual-pole conductor socket near seven-pole
conductor socket as shown. Determine location and
drill 2" hole through trailer skin.
STEP 3: Fasten conductor socket to trailer with screws G, at
washers JJ and nuts Y.
smartwire™
smartwire™ from dual-
conductor socket
WIRING SCHEMATIC
DUAL CONDUCTOR
G
Y
secure
w/cable tie
swap wires to
reverse motor
direction
OPERATION:
A) Close tarp: Push switch to “CLOSE” and hold. Observe tarp
and release switch when tarp is fully closed.
B) Open tarp: Push switch to “OPEN” and hold. Observe tarp
and release switch when tarp is fully open.
STEP 2: Check motor direction
by activating switch to
“OPEN.” If switch is
running system back-
wards, swap wire leads
on two outside tabs on
rocker switch.
NOTE: Wire lengths are predetermined. Before installing
SMARTwire™ components, review and conrm wire routing
so wires reach components with ample room for connection.
front of trailer
JJ

P/N 1124662 Rev. F
15
Wireless Receiver - Cab Wiring
electric
motor
mount circuit breaker
as close to power
supply as possible
Item Part # Description
1. 1126863 Shur-Co® Wireless Receiver -
SMART3™ SMARTwire™
2. 1125007 Shur-Co® Wireless Receiver -
SMART2™ SMARTwire™
3. 1115385 Heavy-Duty Dual-Conductor Plug
4. 1120670 SMARTwire™ Dual-Conductor Socket
5. 1704751 Harness Lock Pin
6. 1703282 Rubber Grommet - 1 1/4" Insert
7. 1702108 Wire Clip - 3/4"
8. 1704354 40-Amp Modied-Reset Circuit Breaker
9. 1704330 Rubber Boot (not shown)
10. 1703244 Ring Terminal - 6 Ga. x 3/8" Stud
E. 1704338 Self-Tapping Screw - 1/4" x 1"
G. 1701045 Cap Screw - 5/16" x 3/4"
H. 1702926 Cap Screw - 5/16" x 7/8"
Y. 1704946 Flanged Top Lock Nut - 5/16"
BB. 1700419 Lock Nut - 5/16"
JJ. 1700427 Flat Washer - 1/4"
LL. 1700428 Flat Washer - 5/16"
2
3
4
8
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
7
6
G
H
NOTICE
Do not power any Shur-Co®wireless system
with battery charger alone, as this will likely
cause system abnormalities and/or system
malfunction. Instead, use 12-volt truck/auto-
mobile battery to provide power to trailer.
!
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.
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
D
1
10
Y
5
LL
BB
JJ
NOTE: Only one electric tarp
system can be hooked up at a time.

P/N 1124662 Rev. F
16
Wireless Receiver - Trailer Mounting & Wiring
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
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.
mark & drill
four 5/16" holes
align holes
in wireless
receiver
w/hole in
trailer
2" hole in trailer
STEP 3: Install grommet into 2" hole. Insert wire from wireless
receiver through grommet.
wire from
wireless
receiver
grommet
2" hole
SHUR-CO®WIRELESS RECEIVER
drill 2" hole
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.
STEP 4: Align holes on wireless receiver with holes on trailer.
Fasten receiver to trailer with 5/16" x 7/8" cap screws,
lock washers and nuts. Adhere warning decal P/N
1705546 above receiver in location shown.
wireless
receiver
apply
warning decal
p/n1705546
H
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™ plug from wireless receiver to SMARTwire™
from dual-conductor socket. Secure connections with
lock pins. If you have SMART2™ or SMART3™ sys-
tem, connect encoder wire from receiver to encoder
wire from motor. 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
WIRING SCHEMATIC
secure w/
cable tie
encoder wire for smart1+™
& smart2™ systems
BB
LL

P/N 1124662 Rev. F
17
Wireless Receiver - Trailer Mounting & Wiring - continued
STEP 3: Fasten conductor socket to trailer with screws G, at
washers JJ and nuts Y.
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
reach components with ample room for connection.
STEP 1: Locate dual-pole conductor socket near seven-pole
conductor socket as shown. Determine location and
drill 2" hole through trailer skin.
CAUTION
Do not fasten SMARTwire™ components to trailer
through hopper walls.
!
smartwire™
G
Y
front of trailer
electric
motor
encoder
wire for
smart2™ &
smart3™
systems
decal
p/n1705546
JJ