Shurco 4500 HD Series User manual

Aluminum System for End Dumps
P/N 1121683 Rev. H

Shur-Co®, LLC Terms & Conditions
SHIPPING. Orders are shipped F.O.B. from the Shur-Co®, LLC sites listed
below. 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 short-
ages 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 separate-
ly. 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
replacement product, are not covered under this warranty. All expenses asso-
ciated 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
expressly 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® of TEXAS
34505 I-10 West, S. Frontage Rd.
Brookshire, TX 77423
Ph 866.689.0039 | 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 COLORADO
10220 Brighton Rd., Unit #1
Henderson, CO 80640
Ph 866.355.9173 | 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 1121683 Rev. H

4500 Series HD for End Dump
P/N 1121683 Rev. H
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 cau-
tion, 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 to your system.
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.
!
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. 13/32" Drill Bit
14. 3/8" Drill Bit
15. 1/4" Drill Bit
16. 17/64" Drill Bit
17. 3/8" Drill
18. 2" Hole Saw
19. Standard/Flathead Screwdriver
20. #2 Phillips Screwdriver
21. Utility Knife
22. Ratchet
23. Hack Saw (metal cutter)
24. Pliers
25. Snap Ring Pliers
26. Wire Cutters
27. Grinder
28. Tape Measure
Hardware Identication....................................................................... 1
Vertical Front Pivot Bracket ............................................................... 2
Sloped Front Mounting Bracket.......................................................... 3
Sloped Front Pivot Bracket................................................................. 4
Rear Pivot Bracket.............................................................................. 5
Front Flex Arm & Electric Motor ......................................................6-7
Rear Flex Arm..................................................................................8-9
Roll Tube Extension.....................................................................10-13
Electric Mounting & Wiring ..........................................................14-18
Change to Manual Power................................................................. 19
Electric Motor Replacement ............................................................. 20
Replacement Parts......................................................................21-23
Inspect all parts in your 4500 Series Electric kit upon arrival. Please
inspect your tarping system regularly, and repair or replace parts when
continued use could damage your system.
TOOLS REQUIRED
RUST PREVENTION
SAFETY
MESSAGE TO OWNERS
TABLE OF CONTENTS
PARTS INSPECTION
1. Always wear safety glasses during instal-
lation and operation.
2. Stay clear of moving parts.
3. No other use of this system is authorized,
except as designed.
SAFETY INSTRUCTIONS

P/N 1121683 Rev. H
Hardware Identication
1
1700411 Hex Nut - 5/16"
1700429 Flat Washer - 3/8"
1700418 Centerlock Nut - 3/8"
1703487 Cap Screw - 5/16" x 1 1/2"
1700419 Nylon Lock Nut - 5/16"
1701045 Cap Screw - 5/16" x 3/4"
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"
1201022 Cap Screw - 5/16" x 3 1/2"
1702890 Flat Washer - 1 1/4"
1701543 Nylon Lock Nut - 1/4"
1700427 Flat Washer - 1/4"
1700400 Self-Tapping Screw - 3/8" x 1"
1700428 Flat Washer - 5/16"
1704264 Cap Screw - 3/8" x 2" - Grade 8
C
D
E
F
G
H
J
N
P
Q
S
a
b
e
1702573 Cap Screw - 3/8" x 2 1/2"
c
O
NOTE: Use lock washers and nuts with self-
tapping screws whenever possible. A minimum
material thickness of 3/16" is required in order
to use self-tapping screws without lock washers
and nuts. Drill 13/32" holes if lock washers and
nuts are used; drill 5/16" holes if lock washers
and nuts are not used.
R
Z
B
1701580 Nylon Lock Nut - 3/8"
f
1701059 Cap Screw - 5/16" x 1"
K
1702926 Cap Screw - 5/16" x 7/8"
L
1700381 Cap Screw - 1/4" x 1"
M
1704308 Hex Flange Cap Screw - #10 x 1/2"
A
d
1700433 Lock Washer - 5/16"
1700398 Self-Drilling Screw - 1/4" x 3/4"
1704367 Hex Flange Cap Screw - #10 x 3/4"
1700403 Self-Tapping Screw - 1/4" x 3/4"
1700436 Lock Washer - 1/4"
g
1701455 Carriage Bolt - 5/16" x 2 1/2"
1700408 Hex Nut - 1/4"
1702653 Cap Screw - #10
U
V
Y
W
T
X
1704931 Flanged Nylon Lock Nut - 5/16"

P/N 1121683 Rev. H Vertical Front Pivot Bracket
2
Slot in pivot pin must face downward.
6"
DRIVER SIDEPASSENGER SIDE
center line
locate center of pivot
inside shaded area
pivot
bracket
42"
3"
3"
STEP 1: Locate front pivot mount bracket on passenger side
of trailer so center of pivot lies within shaded area
shown below. Measure 42" down from top of cap or
44" from top of windshield.
STEP 2: Hold pivot mount brackets in place. Using brackets
as guide, mark hole locations.
STEP 3: Remove rivets and mount brackets into rivet holes
where possible. Otherwise, drill 5/16" holes in trailer.
Fasten bracket to trailer with 3/8" self-tapping screws,
at washers, lock washers and nuts.
drill
13/32"
holes
pivot
bracket
NOTE: Mount brackets into support braces on trailer, if
possible. Reinforce mounting area for adequate support if
bracket cannot be mounted into support braces.
NOTE: Before drilling any holes, make sure ex arm has a
clear pathway to operate.
pivot bracket
pivot pin
STEP 4: Fasten pivot pin to pivot bracket with 3/8" x 1 1/4" cap
screws, at washers, lock washers and nuts.
Item Part # Description
1. 1116919 Vertical Pivot Mount Bracket
2. 1116920 Pivot Pin - 4 Spring
K. 1700400 Self-Tapping Screw - 3/8" x 1"
L. 1702891 Cap Screw - 3/8" x 1 1/4"
W. 1700407 Hex Nut - 3/8"
d. 1700434 Lock Washer - 3/8"
e. 1700429 Flat Washer - 3/8"
1
2
K
W
e
L
e
W
d
d
L
e
W
e
W
K
e
d
d
e

P/N 1121683 Rev. H
Sloped Front Mounting Bracket
3
40"
top rail
front cap
extension bracket
2"
STEP 1: Locate extension brackets 40" down from top of front
cap. Mark line on box parallel to top rails on front and
outer sides of cylinder box.
STEP 3: Using bracket as guide, mark and drill 5/16" holes at
two slots and fasten bracket to cylinder box with 3/8"
x 1" self-tapping screws and at washers.
STEP 2: Align front edge of extension bracket 2" past farthest
point of front cap. Cut back end of bracket to t.
STEP 4: Align center of sloped front mounting bracket with
center of trailer. Fasten sloped front bracket to exten-
sion brackets with 3/8" x 1" self-tapping screws, at
washers and centerlock nuts.
mark
1
2
3
4
Item Part # Description
1112310 Extension Support Bracket
2. 1113306 Universal Extension Bracket - Pass. Side
3. 1113307 Universal Extension Bracket - Driver Side
4. 1112178 Sloped Front Mounting Bracket
K. 1700400 Self-Tapping Screw - 3/8" x 1"
e. 1700429 Flat Washer - 3/8"
X. 1700418 Centerlock Nut - 3/8"
extension
bracket
cylinder box
extension
bracket
cut bracket
here, if needed
extension
bracket
support
brackets
TIP: Use carpenter’s square
to align sloped front bracket
with extension brackets.
sloped front bracket
center
line
STEP 6: Drill 5/16" holes into cylinder box at remaining slots in
extension brackets. Fasten with 3/8" x 1" self-tapping
screws and at washers. Square up brackets with front
of trailer. Tighten all bolts.
STEP 5: Fasten support brackets to extension brackets and
cylinder box with 3/8" x 1" self-tapping screws, at
washers and centerlock nuts.
NOTE: Square up front brackets
with trailer. Align brackets parallel
to top rails.
NOTE: Tighten bolts
just enough to hold
bracket in place.
X
e
K
X
e
K
K
e
X
K
e
K
e
X
X
Ke

P/N 1121683 Rev. H Sloped Front Pivot Bracket
4
Item Part # Description
1. 1116919 Vertical Pivot Mount Bracket
2. 1116920 Pivot Pin - 4 Spring
K. 1700400 Self-Tapping Screw - 3/8" x 1"
L. 1702891 Cap Screw - 3/8" x 1 1/4"
W. 1700407 Hex Nut - 3/8"
d. 1700434 Lock Washer - 3/8"
e. 1700429 Flat Washer - 3/8"
1
2
STEP 3: Mark and drill 5/16" holes. Fasten pivot bracket to
mounting bracket with 3/8" x 1" self-tapping screws,
at washers, lock washers and nuts.
pivot bracket
pivot pin
Slot in pivot pin must face downward.
STEP 4: Fasten pivot pin to pivot bracket with 3/8" x 1 1/4" cap
screws, at washers, lock washers and nuts.
STEP 2: Hold pivot mount brackets in place. Using brackets
as guide, mark hole locations.
NOTE: Before drilling any holes, make sure ex arm has
clear pathway to operate.
6"
DRIVER SIDEPASSENGER SIDE
locate center of pivot
inside shaded area
center of pivot
STEP 1: Locate front pivot mount bracket so center of pivot
lies on passenger side of center line within shaded
area shown below.
center line
L
L
e
d
W
Ke
e
d
W
e
d
eW
e
K
dW

P/N 1121683 Rev. H
Rear Pivot Bracket
5
STEP 1: To determine rear pivot mount bracket location, align
bearing hole in upper ex arm with roll tube under
latchplate. Hold upper ex arm parallel to side of
trailer and lift lower ex arm up so center of pivot is
39" to 45" below top of rear cap.
STEP 2: Mark and drill 5/16" holes in trailer. Fasten bracket
to trailer with 3/8" self-tapping screws, lock washers
and nuts.
pivot mount
bracket
pivot pin
STEP 3: 0"-10" hinge depth. Fasten pivot pin to bracket with
3/8" x 1 1/4" cap screws, at washers, lock washers
and nuts.
Item Part # Description
1. 1116919 Vertical Pivot Mount Bracket
2. 1116920 Pivot Pin - 4 Spring
3. 1116994 Pivot Mount Bracket - Sloped
K. 1700400 Self-Tapping Screw - 3/8" x 1"
L. 1702891 Cap Screw - 3/8" x 1 1/4"
W. 1700407 Hex Nut - 3/8"
d. 1700434 Lock Washer - 3/8"
e. 1700429 Flat Washer - 3/8"
Slot in pivot pin must face downward.
1
2
3
11"-17"
hinge
depth
39"- 45"
30"
upper flex arm
parallel to
side of trailer
lift lower
flex arm
center of pivot
pivot mount
bracket
pivot mount
bracket
0"-10"
hinge
depth
NOTE: If pivot pin cannot be located in recommended area
because of grain doors, pivot arm may be located 30" to 45"
below top of cap.
NOTE: Rear pivot mount bracket may be located anywhere
on rear of trailer as long as upper ex arm is parallel with side
of trailer when tarp is closed and rolled up under latchplate.
L
L
Wd
Wd
e
Je
Wd
K
e
W
d
K
e
Wd
K
W
d
e
e

P/N 1121683 Rev. H
NOTE: Motor assembly on upper ex arm must face toward
trailer as shown.
Front Flex Arm & Electric Motor
6
1
pivot mount
bracket assembly
3
2
STEP 1: Assemble spacer washers onto pivot pin.
pivot pin
5
4
6D
Item Part # Description
1. 1121997 Flex Arm Assembly w/Motor - 7 1/4" -
HD End Dump
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
D. 1700398 Self-Drilling Screw - 1/4" x 3/4"
N. 1701455 Carriage Bolt - 5/16" x 2 1/2"
V. 1704931 Flanged Nylon Lock Nut - 5/16"
f. 1118318 Spacer Washer - 1/4" x 1.28"
g. 1702890 Flat Washer - 1 1/4"
f
g
f
7
V
N
8
9
flex arm joint
lower flex arm
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 5/16" x 2 1/2" carriage bolts and lock nuts.
bellow plate
w/square holes
bellow plate
w/round holes
N
V
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.
!

P/N 1121683 Rev. H
Front Flex Arm & Electric Motor - continued
7
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 1/4" x 3/4" self-drilling screw.
STEP 4: Secure with 1 1/4" at washer and retaining ring.
g
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.

P/N 1121683 Rev. H Rear Flex Arm
8
Item Part # Description
1. 1116990 Gate Flex™
2. 1704892 Cap Plug
3. 1704703 Flange Bearing - 20mm - 2 Bolt
4. 1121649 Upper Flex Arm - Gate Flex™
5. 1121655 Flex Arm Joint Assembly
6. 1700445 Spring Pin - 1/4" x 1 1/2"
7. 1121999 Lower Flex Arm w/Warning Decals
8. 1702888 Retaining Ring - 1 1/4"
9. 1117033 Spacer Tube - .35" x 2 5/8"
10. 1111027 Spiral Torsion Spring
11. 1116994 Pivot Bracket - Sloped
12. 1121414 Bellow Plate - Square Holes
13. 1121413 Bellow Plate - Round Holes
14. 1704891 End Fitting - 4500 HD Series
15. 1704775 Bellow - 4500 HD Series
16. 1701360 Spring Pin - 1/4" x 1 3/4"
J. 1703487 Cap Screw - 5/16" x 1 1/2"
M. 1704264 Cap Screw - 3/8" x 2" - Grade 8
N. 1701455 Carriage Bolt - 5/16" x 2 1/2"
O. 1201022 Cap Screw - 5/16" x 3 1/2"
P. 1702573 Cap Screw - 3/8" x 2 1/2"
U. 1700419 Nylon Lock Nut - 5/16"
V. 1704931 Flanged Nylon Lock Nut - 5/16"
Y. 1701580 Nylon Lock Nut - 3/8"
b. 1700428 Flat Washer - 5/16"
f. 1118318 Spacer Washer - 1/4" x 1.28"
g. 1702890 Flat Washer - 1 1/4"
1
2
4
3
10
8
7
5
spring support
bracket on
lower flex arm
spacer tube
9
NOTE: Insert cap screw through ex arm so head of screw is
on inside of assembly (toward trailer). Warning label must be
in plain view on outside of assembly.
11
STEP 1: Install cap plug on lower ex arm. Fasten spacer
tube into spring support bracket on lower ex arm
with 5/16" x 3 1/2" cap screw, two at washers and
lock nut.
6
2
cap plug
warning decal
Y
P
J
U
Y
M
f
O
U
b
Z
b
O
b
b
U
STEP 2: Install cap plug on rear upper ex arm.
cap plug
upper flex arm
STEP 3: Thread end tting onto end of ex arm joint. Tighten
so end tting is parallel to existing end tting.
flex arm
joint
end fitting
end fitting
15
13
13
12
12
14
N
N
V
V
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.
!

P/N 1121683 Rev. H
Rear Flex Arm - continued
9
STEP 5: Align holes in end ttings and bellow plates with holes
in lower ex arm assembly as shown. Temporarily
install 5/16" x 2 1/2" carriage bolts and lock nuts.
lower flex
arm assembly
upper
flex arm
assembly
STEP 9: Secure with 1 1/4"
at washer and
retaining ring. g
retaining
ring
N
V
bellow plate
w/square holes
upper flex arm
flex arm joint
assembly
bellow
STEP 4: Insert ex arm joint into upper ex arm and slide
bellow over ex arm joint. Align holes in upper ex
arm, bellow plates, ex arm joint and bellow. Fasten
with 5/16" carriage bolts and anged nylon lock nuts.
V
N
bellow plate
w/square hole
bellow plate
w/round hole
STEP 8: Position ange bearings as shown and fasten to bearing
mount plate with 3/8" x 2" cap screws and lock nuts.
bearing
mount
plate
M
Y
WARNING
Flex arms are under tension while torsion springs are
engaged. Use caution while assembling and disas-
sembling arms. Failure to read and follow instructions
could result in serious injury or death.
!
bellow plate
w/round holes
STEP 6: Assemble
spacer washers
onto pivot pin.
f
pivot pin
STEP 7: Assemble spiral torsion springs and lower ex arm
onto pivot pin. Hook springs over 5/16" x 3 1/2" cap
screw and spacer tube.
pivot pin
lower flex arm
spiral torsion
springs
pinned end fitting
NOTE: Do not tighten
nuts as adjustments
will be made later. See
“Roll Tube Extension”

P/N 1121683 Rev. H
10
align upper flex arm
parallel to back of trailer
upper
flex arm
roll tube
STEP 4: On vertical trailers, align upper ex arm in vertical
plane 90° to roll tube. On sloped trailers, align upper
ex arm parallel to back of trailer. Tighten set screws
in ush mount bearing.
VERTICAL TRAILER
align upper flex arm on vertical
plane 90° to roll tube
roll tube
vertical plane
upper
flex
arm
90°
STEP 3: Slide bearing shaft on Gate Flex™ through ange
bearing on upper ex arm. Drill 5/16" hole through
bearing shaft. Insert 5/16" x 1 1/2" cap screw through
hole and secure with lock nut.
flange bearing
bearing shaft
on gate flex™
1"
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.
!
tighten set
screws
tighten set
screws
drill 5/16"
hole
NOTE: Do not leave unattended until ex arm is securely
fastened to roll tube extension as shown.
SLOPED TRAILER
Roll Tube Extension
gate hinge pin
splined shaft
STEP 1: Adjust roll tube forward or backward to align end of
splined shaft with gate hinge pin.
adjust roll tube
NOTE: If hinge depth is 0" to 4", set end of splined shaft 4" in
from back of gate.
STEP 2: Slide Gate Flex™ completely over splined shaft on
roll tube. Fasten with 3/8" x 2 1/2" cap screw and
centerlock nut.
NOTE: Do not remove splined shaft. Splined shaft will be
needed if system is switched to manual operation.
gate flex™
splined shaft
Y
P
U
J
REAR OF TRAILER

P/N 1121683 Rev. H
11
STEP 3: 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 as shown.
vertical plane
vertical plane
flex
arm
roll tube
roll tube
flex arm
roll tube
extension
roll tube
extension
mark location
to be cut
face panel
90°
90°
sloped trailer
vertical trailer
NOTE: Two people are required for safe installation.
mark location
to be cut
STEP 2A: Slide motor spacer over motor shaft.
STEP 2B: Slide roll tube extension over motor shaft. Fasten with
3/8" x 2" cap screws and lock nuts. Finger tighten only.
motor
spacer
motor shaft
roll tube
extension
motor shaft
Roll Tube Extension - continued
STEP 1: Slide tarp back onto roll tube.
roll tube roll tube
vertical trailer sloped trailer
4
5
3
2
1
7
Y
C
M
M
Y
Item Part # Description
1. 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. 1120681 Motor Mount Bearing Retainer
5. 1120679 Motor Spacer
7. 1120699 Roll Tube Extension w/Drive Shaft - 74.87"
8. 1704982 4500 Series HD Motor Cover - Black
C. 1704367 Hex Flange Cap Screw - #10 x 3/4"
M. 1704264 Cap Screw - 3/8" x 2" - Grade 8
S. 1701543 Nylon Lock Nut - 1/4"
Y. 1701580 Nylon Lock Nut - 3/8"
8
S
FRONT OF TRAILER

P/N 1121683 Rev. H
12
Roll Tube Extension - continued
STEP 6: Insert swaged end of roll tube extension w/drive shaft
into roll tube. Align extension straight with roll tube
and align holes. Weld as shown and grind smooth.
STEP 5: Mark and drill 3/8" holes through roll tube at right
angles to each other in locations shown.
drill 3/8"
holes
through
roll tube
9"
13"
insert
fill holes
with weld
& grind
smooth
weld all around &
grind smooth
NOTE: To prevent rust, paint all weld seams and/or metal
exposed by grinding or cutting with corrosion-resistant paint.
face panel
pivot bracket
electric
motor
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 tarping system will roll smoothly.
STEP 7: Slide roll tube/roll tube extension weldment back into
position and align upper ex arm on front of trailer. Follow
steps 6 to 7 to install motor, positioning motor as shown
below. Make sure torsion springs load when tarp opens.
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.
!
STEP 8: Refasten and secure roll tube to electric motor shaft
with 3/8" x 2" cap screw and lock nut. Install bear-
ing spacers, radial ball bearings and bearing mount
retainer. Secure with 1/4" lock nuts.
roll
tube
electric motor
bearing
mount
retainer
radial
ball bearing
bearing
spacer
STEP 4: Unfasten and remove motor mount assembly from
roll tube extension. Remove roll tube extension from
roll tube. Cut roll tube at marked location.
M
Y
S

P/N 1121683 Rev. H
13
NOTE: Verify that ex arm is on vertical plane and parallel to
face panel before proceeding. Make sure all fasteners holding
motor to upper ex arm bracket are tightened securely.
STEP 10: Place wrench on ex arm joint next to lower ex arm.
Turn ex arm joint counter-clockwise (up) to move
upper ex arm and Gate Flex™ from side to side.
drill 1/4" hole
spring pin
rear of
trailer
top view
flex arm & gate flex™
will move side to side
turn counter-
clockwise (up)
STEP 12: Drill 1/4" hole through lower ex arm and ex arm joint
as shown. Install 1/4" x 1 3/4" spring pin into drilled hole.
STEP 11: Keep turning ex arm joint until Gate Flex™ is parallel
to side of trailer and at 90° angle to rear door. Do not
overtighten.
90°
7/16"
STEP 9: Refasten tarp to roll tube with existing U-clamps and
screws. Tighten all fasteners securely. Tighten front
and rear ex arm connections.
flex arm joint
lower flex arm
Roll Tube Extension - continued
NOTE: Do not overtighten
or plastic insert will break.
or less
REAR OF TRAILER
STEP 13: Remove tension from rear arm by lowering roll tube
to lowest position on side of trailer. Disconnect Gate
Flex™ from splined shaft on roll tube. Remove carriage
bolts and plates from lower arm. Slide bellow into posi-
tion and re-assemble carriage bolts and plates. Tighten
nuts and reconnect Gate Flex™ to splined shaft.

P/N 1121683 Rev. H
14
Rocker Switch - Cab Wiring
electric
motor
Item Part # Description
1. 1703661 Mounting Bracket - Rocker Switch
2. 1116020 Rocker Switch
3. 1703845 Motor-Reversing Solenoid
4. 1109015 Mounting Bracket
5. 1115385 Heavy-Duty Dual-Conductor Plug
6. 1115386 Heavy-Duty Dual-Conductor Socket
7. 1704354 40-Amp Modied-Reset Circuit Breaker
8. 1704573 Conductor Socket Sealed Boot
9. 1703245 Ring Terminal - 6 Ga. x #10 Stud
10. 1703244 Ring Terminal - 6 Ga. x 3/8” Stud
11. 1704153 Ring Terminal - 14 Ga. x 1/4” Stud
12. 1703659 Push-On Terminal - 14 Ga. 1/4”
13. 1702707 Ring Terminal - 6 Ga. 1/4 Stud
E. 1700381 Cap Screw - 1/4" x 1"
F. 1701045 Cap Screw - 5/16" x 3/4"
K. 1700400 Self-Tapping Screw - 3/8" x 1"
S. 1701543 Nylon Lock Nut - 1/4"
T. 1700411 Hex Nut - 5/16"
W. 1700407 Hex Nut - 3/8"
d. 1700434 Lock Washer - 3/8"
3
2
4
7
1
5
6
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 in diagram. Run 14-ga. wires from
solenoid to switch.
STEP 1: Mount circuit breaker as close as possible to battery
or power supply.
battery
rocker
switch
relay solenoid
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
circuit
breaker
jumper wire
provided
conductor plug
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
E
S
F
K
T
d
W
NOTE: Only one electric tarp
system can be hooked up at a time.
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.
9
13
12
11
10

P/N 1121683 Rev. H
15
Rocker Switch - Trailer Mounting & Wiring
STEP 1: Mount bracket at suitable location on front of trailer,
usually near existing plugs. Mark and drill 5/16" holes
and fasten with 3/8" x 1" self-tapping screws, lock
washers and nuts.
drill 5/16" holes
mounting bracket
STEP 2: Fasten conductor socket to mounting bracket with
5/16" x 3/4" cap screws and lock nuts.
negative
(ground) wire
positive wire -
colored stripe
on top
sealed boot
cable tie
conductor socket
mounting bracket
Bring 6-ga. wire from lower end of pivot arm through sealed boot.
Connect wire ends to conductor socket, aligning positive wire on
socket with positive wire on conductor plug. Slide sealed boot
against conductor socket and secure boot to wire with cable tie.
conductor socket/
bracket assembly
STEP 3: Fasten motor cover onto motor with #10 x 3/4" screws.
motor
cover
motor
W
d
K
F
T
C
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.
front view of trailer
CAUTION
Do not cut SMART-
wire™. Bind excess
wire with cable ties.
!
to conductor

P/N 1121683 Rev. H
16
CAUTION
Check all hardware for complete assembly
before operating. Inspect system at this time
and adjust as required.
!
NOTE: Coat each connection with dielectric grease (P/N
1704378) to prevent corrosion.
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
smartwire™ to dual-
conductor socket
WIRING SCHEMATIC
secure
w/cable
tie
Rocker Switch - Trailer Mounting & Wiring - continued
swap wires to
reverse motor
direction
STEP 2: Check motor direction by activating switch to OPEN. If
switch is running system backwards, program remote
to wireless receiver (see programming instructions)
and rewire as directed in Troubleshooting Guide.
close
open
to conductor
6-ga. wire
conductor socket
smartwire™ socket
positive
red wire
on top
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.
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.

P/N 1121683 Rev. H
17
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. 1125007 Shur-Co® Wireless Receiver - S2
1125021 Shur-Co® Wireless Receiver - S1+
2. 1109015 Mounting Bracket
3. 1115385 Heavy-Duty Dual-Conductor Plug
4. 1115386 Heavy-Duty Dual-Conductor Socket
5. 1704573 Conductor Socket Sealed Boot
6. 1703282 Rubber Grommet - 1 1/4" Insert
7. 1702108 Wire Clip - 3/4"
8. 1704338 Self-Tapping Screw - 1/4" x 1"
9. 1704354 40-Amp Modied-Reset Circuit Breaker
10. 1703244 Ring Terminal - 6 Ga. x 3/8" Stud
11. 1704330 Rubber Boot (not shown)
F. 1701045 Cap Screw - 5/16" x 3/4"
G. 1702926 Cap Screw - 5/16" x 7/8"
K. 1700400 Self-Tapping Screw - 3/8" x 1"
T. 1700411 Hex Nut - 5/16"
U. 1700419 Lock Nut - 5/16"
W. 1700407 Hex Nut - 3/8"
b. 1700428 Flat Washer - 5/16"
d. 1700434 Lock Washer - 3/8"
1
2
3
4
9
5
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
8
6
W
d
K
F
G
U
b
T
NOTE: Only hook up one electric tarp system at a time.
NOTICE
Do not power any Shur-Co®wireless
system with battery charger alone, as
this will likely cause system abnormali-
ties and/or system malfunction. Instead,
use 12-volt truck/automobile battery to
provide power to trailer.
!
10