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Shurco 4500 HD Series Owner's Manual

Aluminum system for live-bottom trailers
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P/N 1121682 Rev. K
Aluminum System
for Live-Bottom Trailers

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  • Page 1 P/N 1121682 Rev. K Aluminum System for Live-Bottom Trailers...
  • Page 2 Fax +44 (0)871.272.8278 SHUR-CO of MICHIGAN ® Ph 866.356.0246 | Fax 217.877.8270 5100 Lakeshore Dr. SHUR-CO of OHIO ® For more info, log on to our website: Lexington, MI 48450 www.shurco.com Ph 866.356.0242 | Fax 330.297.5599 Ph 800.327.8287 | Fax 772.287.0431...

  • Page 3: Table Of Contents

    4500 Series HD for Live-Bottom Trailer P/N 1121682 Rev. K MESSAGE TO OWNERS TABLE OF CONTENTS Thank you for buying this tarping system from Shur-Co . We appreci- ® ate your confidence in our products. Please read and thoroughly un- Hardware Identification ...............1 derstand this manual before installing and/or operating this system.

  • Page 4: Hardware Identification

    P/N 1121682 Rev. K Hardware Identification 1701580 Nylon Lock Nut - 3/8" 1704367 Cap Screw - #10 x 3/4" 1700381 Cap Screw - 1/4" x 1" 1700436 Lock Washer - 1/4" 1700403 Self-Tapping Screw - 1/4" x 3/4" 1700427 Flat Washer - 1/4" 1701045 Cap Screw - 5/16"...

  • Page 5: Front Pivot Bracket/Pivot Pin Installation

    P/N 1121682 Rev. K Front Pivot Bracket Installation NOTE: Read entire section before drilling holes. Determine if rivets on front of trailer are centered or off center. HORIZONTALLY CORRUGATED TRAILERS FRONT OF TRAILER STEP 1: Locate front pivot mount bracket on passenger side NOTE: Use pivot bracket washers only when horizontal of trailer so center of pivot lies within shaded area corrugation on trailer skin prevents bracket from contacting skin.

  • Page 6: Front Flex Arm & Electric Motor Installation

    P/N 1121682 Rev. K Front Flex Arm & Electric Motor Installation NOTE: Do not remove cable tie pivot mount from front flex arm and motor bracket assembly assembly until installation is complete. See step 9. Item Part # Description Flex Arm Assembly - Std. Flex Arm Assembly - 7 1/4"...
  • Page 7 P/N 1121682 Rev. K Front Flex Arm & Motor Installation - continued STEP 3: Assemble spiral torsion springs and lower flex arm onto pivot pin. Hook springs over 3/8" x 3 1/2" cap screw and spacer tube. NOTE: Wire lengths are predetermined. Before installing SMARTwire™...

  • Page 8: Rear Mounting Beam & Pivot Bracket Installation

    P/N 1121682 Rev. K Rear Mounting Beam & Pivot Bracket Installation Item Part # Description 1116920 Pivot Pin - 4 Spring 1116919 Vertical Pivot Mount Bracket 1117767 Low-Profile Pivot Mount Bracket ___*___ Mounting Beam 1117816 Pivot Bracket - Side Hinge H.

  • Page 9: Rear Flex Arm Installation - Top Hinge

    P/N 1121682 Rev. K Rear Flex Arm Installation - Top Hinge Item Part # Description 1116990 Gate Flex™ 1111027 Spiral Torsion Spring 1121649 Upper Flex Arm - Gate Flex™ 1702888 Retaining Ring - 1 1/4” 1121999 Lower Flex Arm w/Warning Decals 1117033 Spacer Tube - .35"...
  • Page 10 P/N 1121682 Rev. K Rear Flex Arm Installation - Top Hinge - continued STEP 6: Assemble spacer washers onto pivot pin. pivot pin STEP 4: Insert flex arm joint into upper flex arm and slide bellow over flex arm joint. Align holes in upper flex arm, bellow plates, flex arm joint and bellow.

  • Page 11: Rear Flex Arm Installation - Side Hinge

    P/N 1121682 Rev. K Rear Flex Arm Installation - Side Hinge pivot pin Item Part # Description 1117777 Roll Tube Bearing Pack 1121680 Upper Flex Arm Joint Assembly 1121738 Upper Flex Arm - Side Hinge 1700445 Spring Pin - 1/4" x 1 1/2" 1704775 Bellow 1121999 Lower Flex Arm w/Warning Decals 1702888 Retaining Ring - 1 1/4"...
  • Page 12 P/N 1121682 Rev. K Rear Flex Arm Installation - Side Hinge - continued STEP 6: Assemble spiral torsion springs and lower flex arm onto pivot pin. Hook springs over 5/16" x 3 1/2" cap plate w screw and spacer tube. holes plate w holes...

  • Page 13: Roll Tube Extension Installation - Top Hinge

    Roll Tube Extension Installation - Top Hinge P/N 1121682 Rev. K Item Part # Description Flex Arm Assembly w/Motor - Std. 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.
  • Page 14 Roll Tube Extension Installation - Top Hinge - continued P/N 1121682 Rev. K STEP 7: Hold flex arm with motor and roll tube extension in vertical plane to trailer and 90° to roll tube. Mark and STEP 4: Align upper flex arm in vertical plane cut roll tube at location shown.
  • Page 15 P/N 1121682 Rev. K Roll Tube Extension Installation - Top Hinge - continued STEP 10: Slide roll tube/roll tube extension weldment back into position and align upper flex arm on front of trailer. STEP 13: Refasten tarp to roll tube with existing Follow step 11 to install motor, positioning motor as shown below.

  • Page 16: Roll Tube Extension Installation - Side Hinge

    P/N 1121682 Rev. K Roll Tube Installation - Side Hinge WARNING REAR OF TRAILER Flex arms are under tension while torsion springs are engaged. Use caution while assembling STEP 1: Adjust roll tube forward or backward so end of splined and disassembling arms.
  • Page 17 P/N 1121682 Rev. K Roll Tube Installation - Side Hinge - continued STEP 6B: Slide roll tube extension over motor shaft. Fasten with 3/8" x 2" cap screws and lock nuts. Finger tighten only. STEP 8: Unfasten and remove motor from roll tube extension. Remove roll tube extension from roll tube.
  • Page 18 P/N 1121682 Rev. K Roll Tube Installation - Side Hinge - continued STEP 11: Refasten and secure roll tube to electric motor shaft with 3/8" x 2" cap screw and lock nut. Install bear- STEP 10: Slide roll tube/roll tube extension weldment back into ing spacers, radial ball bearings and bearing mount position and align upper flex arm on front of trailer.

  • Page 19: Electric Mounting & Wiring

    P/N 1121682 Rev. K Rocker Switch - Cab Wiring Item Part # Description NOTE: Only one 1703661 Rocker Switch Mounting Bracket electric tarp system 1116020 Rocker Switch 1703845 Motor-Reversing Solenoid can be hooked up 1704751 Harness Lock Pin - 1/4" x 7/8" at a time.
  • Page 20 P/N 1121682 Rev. K Rocker Switch - Trailer Mounting & Wiring CAUTION front of trailer Do not cut SMART- wire™. Bind excess wire with cable ties. WIRING SCHEMATIC STEP 1: Connect SMARTwire™ from electric motor to SMART- wire™ from dual-conductor and secure connection with lock pin.
  • Page 21 P/N 1121682 Rev. K Wireless Receiver - Cab Wiring Item Part # Description 1115385 Heavy-Duty Dual-Conductor Plug 1120670 SMARTwire™ Dual-Conductor Socket 1704751 Harness Lock Pin - 1/4" x 7/8" 1702108 Wire Clip - 3/4" 1704354 40-Amp Modified-Reset Circuit Breaker 1125008 SMART2™ Receiver - Rear Output 1126860 SMART3™...
  • Page 22 P/N 1121682 Rev. K Wireless Receiver - Trailer Mounting & Wiring front of trailer electric motor decal 1705546 encoder wire NOTE: Wire lengths are predetermined. Before installing SMARTwire™ components, review and confirm wire routing so wires reach components with ample room for connection. DUAL-CONDUCTOR SOCKET STEP 1: Locate dual-pole conductor socket near 7-pole con- STEP 3: Fasten conductor socket to trailer with 5/16"...
  • Page 23 P/N 1121682 Rev. K Wireless Receiver - Trailer Mounting & Wiring - continued SHUR-CO WIRELESS RECEIVER ® STEP 1: In order to clear travel area of front arm, locate Shur- WIRING SCHEMATIC wireless receiver as low as possible on front of ®...

  • Page 24: Conversion From Electric To Manual Power

    Operation P/N 1121682 Rev. K press press close tarp open tarp NOTE: 4500 Series HD trailer-mounted control boxes now operate in EXPRESS MODE. Pressing O or C button 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.

  • Page 25: Electric Motor Replacement

    STEP 5: Install crank arm assembly as shown in Shur-Lok ® owner’s manual. Manual may be viewed at http:// www.shurco.com. You may need optional manual override extension kit (P/N 1117022). STEP 2: Carefully slide Gate Flex™ off roll tube. Flex arm will be under tension and have some downward force.
  • Page 26 P/N 1121682 Rev. K Electric Motor Replacement INSTALL NEW MOTOR STEP 1: Install new motor. Fasten motor to motor bracket with REMOVE EXISTING MOTOR 5/16" washers and nuts. STEP 1: Disconnect electric power to trailer. Unfasten and remove motor cover. Unfasten 3/8" x 2" cap screw and lock nut holding motor shaft to roll tube extension.

  • Page 27: Replacement Parts

    P/N 1121682 Rev. K Replacement Parts REAR TOP HINGES Item Part # Description Item Part # Description ___*___ Beam Bracket 19. 1700418 Centerlock Nut - 3/8" 1700400 Self-Tapping Screw - 3/8" x 1" 20. 1702573 Cap Screw - 3/8" x 2 1/2" 1700407 Hex Nut - 3/8"...
  • Page 28 P/N 1121682 Rev. K Replacement Parts NOTE: Replace system parts only with Genuine Shur-Co parts to ensure proper .® system function. If Genuine Shur-Co parts ® are not used, warranty could be void. FRONT ASSEMBLIES Item Part # Description 1120697 Roll Tube Extension w/Drive Shaft - 34.43" 1120698 Roll Tube Extension w/Drive Shaft - 45.37"...
  • Page 29 P/N 1121682 Rev. K Replacement Parts Item Part # Description 17. 1117033 Spacer Tube - .35" x 2 5/8" 18. 1700419 Nylon Lock Nut - 5/16" 19. 1702890 Flat Washer - 1 1/4" REAR SIDE HINGES 20. 1702888 Retaining Ring - 1 1/4" Item Part # Description 21.

  • Page 30: Cap Screw - 5/16" X

    Replacement Parts P/N 1121682 Rev. K encoder wire used in cab rocker switch kits only NOTE: To check remote version, used w 2™ smart replacement go to SETUP, wireless cradle then select systems INFORMATION. 3™ used w smart Call Shur-Co's Help wireless systems Line, if needed.

  • Page 31: Lock Washer -

    Replacement Parts P/N 1121682 Rev. K PIVOT BACKER PLATES Item Part # Description 1700407 Hex Nut - 3/8" 1700434 Lock Washer - 3/8" 1702891 Cap Screw - 3/8" x 1 1/4" 1120361 Pivot Backer Plate - 5" x 16" 1120418 Pivot Backer Plate - 5" x 20"...

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