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EGR RollTrac Training Manual

Jeep gladiator 2020+
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EGR RollTrac Training Manual
JEEP GLADIATOR 2020+
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Products and specifications in this flyer are correct at time of printing. They are subject to change at any time without notice.
© Copyright EGR 2021 Oakmoore Pty Ltd ABN: 13 056 159 570

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  • Page 1 EGR RollTrac Training Manual JEEP GLADIATOR 2020+ Insert CODE Products and specifications in this flyer are correct at time of printing. They are subject to change at any time without notice. © Copyright EGR 2021 Oakmoore Pty Ltd ABN: 13 056 159 570...
  • Page 3 TRAINING MANUAL US 2020+...
  • Page 4 EGR Group. Except for a maximum of one chapter or 10% of this book, whichever is the greater, to be copied by an educational institution for its educational purposes provided that the educational institution (or the body that administers it) has given a remuneration notice.

  • Page 5: Table Of Contents

    ........How To Install The EGR RollTrac For The JEEP Gladiator .

  • Page 6: Welcome

    EGR RollTrac Training Manual - JEEP Gladiator WELCOME This Installation Training manual has been developed to support you to install the EGR RollTrac product. It contains key information including all the skills and knowledge required to achieve competence to become an EGR RollTrac approved installer.

  • Page 7: Introduction

    Watch the following video about the EGR RollTrac. Scan the QR Code to begin the video. The EGR RollTrac is finished in a premium, lightly textured, satin black powder coat that is UV stable and won’t fade over time. The low maintenance design ensures that the cover continues to slide smoothly every time and keeps maintenance to a minimum.

  • Page 8: What's In The Box

    QTY: 6 QTY: 12 EGR RollTrac Training Manual - JEEP Gladiator WHAT’S IN THE BOX CABLE TIE KIT37900 600mm FRONT DRAINAGE TUBE REAR DRAINAGE TUBE QTY: 6 QTY: 2 QTY: 2 EGR ROLLTRAC FITTING KIT COMPONENTS IN BAGS EGR ROLLTRAC FITTING KIT ADDITIONAL ITEMS...
  • Page 9 QTY: 8 QTY: 8 MBAR0010 KIT QTY: 1 SCRW1012 WASH70005 SCREW M6 QTY: 8 QTY: 8 MBAR0010 KIT QTY: 1 EGR ROLLTRAC FITTING KIT IN BOX MISC5539 MISC5422 MISC5420RH MISC5420LH DATUM BRACKET SIDE RAIL BRACKET FRONT MOUNTING BRACKET FRONT MOUNTING BRACKET...

  • Page 10: Workplace Health & Safety (Whs)

    EGR RollTrac Training Manual - JEEP Gladiator WORKPLACE HEALTH AND SAFETY (WHS) You must follow all safety rules and instructions when performing any work. If you are not sure about what you should do, ask your supervisor. They will tell you what you need to do and how to do it in a safe way.

  • Page 11: Personal Protective Equipment

    Make sure any PPE you are wearing is in good condition, fits well and is right for the job. For installation of the EGR RollTrac product, you will need the following PPE: Symbol...

  • Page 12: Tools Required

    EGR RollTrac Training Manual - JEEP Gladiator TOOLS REQUIRED You will need the following tools to install the RollTrac product correctly, make sure they are all in good working order before using: Hole saw Centre Punch Drill Bit – Drill 29mm, 38mm &...
  • Page 13 Step Drill 9mm / 25mm Cordless Angle Grinder Anti-Abrasion Tape ADDITIONAL ITEMS REQUIRED In addition to the EGR RollTrac kit and tools, ensure that you have these extra items listed below: This Training Manual Jeep Gladiator Owner’s Manual Insulation Tape...
  • Page 14 EGR RollTrac product onto a Jeep Gladiator 2020+ correctly and in accordance with the specifications outlined. You will be required to complete the following as part of the installation of the EGR RollTrac product: • WHS check.
  • Page 15 EGR ROLLTRAC STEPS & PREPARATION SECTION A BED PREP START PAGE 11, STEPS 1 - 22 SECTION B ELECTRICAL PAGE 27, STEPS 1 - 21 SECTION C ROLLTRAC ASSEMBLY PAGE 41, STEPS 1 - 28 SECTION D UPDATE ROLLTRAC Page #...

  • Page 16: Bed Preparation (Section A)

    EGR RollTrac Training Manual - JEEP Gladiator 2020+ BED PREPARATION • Due to variations in bed liners it is recommended that installers mark up and pre check part fitment in assembly and adjust trim lines prior to making final cuts.
  • Page 17 BED PREPARATION Step Instruction Image Wash the vehicle to ensure that all dirt and grease is removed. Allow to dry then apply the 50/50 isoproyl (rubbing alcohol) mix to the top surfaces and allow to dry. Using a ratchet or cordless drill, unscrew the bolts, hold in place and gently remove the tail lights.
  • Page 18 EGR RollTrac Training Manual - JEEP Gladiator 2020+ BED PREPARATION Step Instruction Image Using a ratchet or cordless drill, unscrew the M6 bolts holding the Front utility rack bar in place and remove the Front utility bar. (NOTE: The M6 Bolts may require some...
  • Page 19 BED PREPARATION Step Instruction Image Measure across 4.56 inches from the side of the bed, and 8.42 inches down from the top lip of the bed. Mark this position with a center punch and hammer. Drill through the marked position with a 38 millimeter or 1.49 inch hole saw.
  • Page 20 EGR RollTrac Training Manual - JEEP Gladiator 2020+ BED PREPARATION Step Instruction Image On the left hand side of the bed, mark an additional hole for the EGR RollTrac wiring harness. Measure 71 millimeters or 2.79 inches across from the side of the bed and 128 millimeters or 5.03 inches...
  • Page 21 BED PREPARATION Step Instruction Image Open the tailgate. Measure and mark the positions for the rear drain tubes using a tape measure and pen. (A straight edge or ruler may also be used). Measure 1.37 inches across from the edge of the panel, and 0.78 inches in from the side of the bed.
  • Page 22 EGR RollTrac Training Manual - JEEP Gladiator 2020+ BED PREPARATION Step Instruction Image Use a de-burring tool to clean any swarf and sharp edges from the holes. IMPORTANT!! Apply rust inhibitor to the exposed metal. Apply a bead of silicon /...
  • Page 23 Using a nutsert tool, fit the supplied Nutsert into the lower holes in the front corner of the bed, adjacent to the EGR RollTrac header bar. You may need to drill out the hole with a .35 inch drill bit to remove excess spray liner.
  • Page 24 EGR RollTrac Training Manual - JEEP Gladiator 2020+ BED PREPARATION Step Instruction Image Assemble the two front brackets as shown. Thread the two M6 screws halfway, and use the shoulder bolt to hold the datum plate. Attach to the bed and tighten bolts to 4.05 foot pounds of...
  • Page 25 BED PREPARATION Step Instruction Image...
  • Page 26 EGR RollTrac Training Manual - JEEP Gladiator 2020+ BED PREPARATION Step Instruction Image...
  • Page 27 BED PREPARATION Step Instruction Image...

  • Page 28: Knowledge Check & Observation

    EGR RollTrac Training Manual - JEEP Gladiator 2020+ KNOWLEDGE CHECK & OBSERVATION - WHS & BED PREPARATION How would you identify all the components required for an EGR RollTrac install? Answer If correct, Trainer to Tick What Personal Protective Equipment (PPE) is required for...
  • Page 29 KNOWLEDGE CHECK & OBSERVATION - WHS & BED PREPARATION After drilling the bed with the hole saw, you must ______ and ______ to prevent rust. Answer If correct, Trainer to Tick Why must the front and side rail of the tray and inspection covers be sealed with silicone bead? Answer If correct,...
  • Page 30 EGR RollTrac Training Manual - JEEP Gladiator 2020+ BED PREPARATION OBSERVATION Not Yet TASK Competent Competent WORKPLACE HEALTH AND SAFETY Has the installer ensured that the area they are going to be working in has good air flow and set up safety for installation?
  • Page 31 BED PREPARATION OBSERVATION Not Yet TASK Competent Competent BED PREPARATION Has the installer removed any accessories attached to the bed (sports bar, cabin guards)? Has the installer washed the vehicle and bed to ensure that all dirt and grease is removed? Has the installer cleaned the surfaces of the bed and tailgate with the 50/50 isopropyl mix? Has the installer removed all rear fasteners?
  • Page 32 EGR RollTrac Training Manual - JEEP Gladiator 2020+ BED PREPARATION OBSERVATION Not Yet TASK Competent Competent BED PREPARATION Has the installer fit front and rear drain tubes? Has the installer reassembled both tail lights? Has the installer replaced and tightened all the fasteners that were...

  • Page 34: Electrical Loom Installation (Section B)

    EGR RollTrac Training Manual - JEEP Gladiator 2020+ ELECTRICAL LOOM INSTALLATION Step Instruction Image • Cut the Left Hand Side grommet to feed the wire through to the cabin. • Ensure that you colour match the wires accordingly when installing male terminals into two-way connector housing.
  • Page 35 ELECTRICAL LOOM INSTALLATION Step Instruction Image Route the wiring harness down between bed and rear door. Underneath the vehicle, route the wiring harness towards the engine bay along the left hand side chassis rail. Where feasible, loosely attach the wiring harness to the existing vehicle brake line and chassis mounts using cable ties.
  • Page 36 EGR RollTrac Training Manual - JEEP Gladiator 2020+ ELECTRICAL LOOM INSTALLATION Step Instruction Image Make a hole in the grommet just large enough to feed branch B of the wiring harness into the cabin. Pull the harness through the hole in the floor until the round grommet contacts the floor.
  • Page 37 ELECTRICAL LOOM INSTALLATION Step Instruction Image Continue routing branch C and D of the wiring harness towards the front of the vehicle along the right hand side chassis rail. Where feasible, loosely attach the wiring harness to the existing vehicle brake line and chassis mounts using cable ties.
  • Page 38 EGR RollTrac Training Manual - JEEP Gladiator 2020+ ELECTRICAL LOOM INSTALLATION Step Instruction Image Insert the four wires from branch B of the wiring harness into the supplied 4 terminal connector. Ensure that the wires are colour matched to the wires of the supplied T-Patch.
  • Page 39 ELECTRICAL LOOM INSTALLATION Step Instruction Image Feed a draw wire down into the engine bay towards the floor. Bend the end of the draw wire and place it on the edge of the engine bay. Connect the draw wire to the wiring harness with tape.

  • Page 40: Knowledge Check & Observation

    EGR RollTrac Training Manual - JEEP Gladiator 2020+ ELECTRICAL LOOM INSTALLATION Step Instruction Image KNOWLEDGE CHECK & OBSERVATION - ELECTRICAL LOOM INSTALLATION The harness is fed from the engine bay into the cabin by the Left Hand Side access point of the ________ _________.
  • Page 41 KNOWLEDGE CHECK & OBSERVATION - ELECTRICAL LOOM INSTALLATION The Left Hand Side scuff plate, _____, and glovebox are removed to install the loom. Answer If correct, Trainer to Tick If the vehicle is not fitted with an accessory fuse box, the loom is connected to the ________ battery terminal and grounded on the chassis.
  • Page 42 Competent Competent ELECTRICAL LOOM INSTALLATION Has the installer selected the correct parts from the EGR RollTrac kit? Has the installer fed the wiring between the cabin and bed, through the previously drilled hole, until it is sealed by the rubber grommet?
  • Page 43 ELECTRICAL LOOM INSTALLATION OBSERVATION Not Yet TASK Competent Competent ELECTRICAL LOOM INSTALLATION Has the installer connected the positive terminal to the battery correctly/to the accessory fuse box correctly? COMMENTS:...

  • Page 44: Egr Rolltrac Assembly (Section C)

    EGR RollTrac Training Manual - JEEP Gladiator 2020+ EGR ROLLTRAC ASSEMBLY Step Instruction Image • During assembly procedure support the center of the canister by placing on top of boxes or installation area, avoiding scratching surfaces. • Keep connectors away from assembly.
  • Page 45 EGR ROLLTRAC ASSEMBLY Step Instruction Image Retrieve the side rails and wipe with Wax & Grease Remover prior to taping. Use tape to secure the seal in place for installation. (Failure to correctly maintain seal during installation will void warranty).
  • Page 46 EGR RollTrac Training Manual - JEEP Gladiator 2020+ EGR ROLLTRAC ASSEMBLY Step Instruction Image Line up the mounting holes and insert three screws to hold the side rail in place. Moving from front to back, loosely secure the three bolts with an hex key.
  • Page 47 Using a torque wrench and allen key bit, tighten the screws to 5.5 Nm or 4.05 foot pounds of force. Prop up RollTrac canister using cardboard blocks from packaging. Retrieve the utility box and install it to the canister.
  • Page 48 EGR RollTrac Training Manual - JEEP Gladiator 2020+ EGR ROLLTRAC ASSEMBLY Step Instruction Image Open the lid of the utility box. Using a torque wrench, fasten the utility box to the canister, tightening the 5 screws to 9 Nm or 6.63 foot pounds of torque.
  • Page 49 EGR ROLLTRAC ASSEMBLY Step Instruction Image Install the foam tape to the side rail, trimming if required to ensure that it makes contact with the front cover seal. Clean the surface of the side rail with alcohol wipes or spray and apply surface primer if required.
  • Page 50 EGR RollTrac Training Manual - JEEP Gladiator 2020+ EGR ROLLTRAC ASSEMBLY Step Instruction Image Using an allen key, fit the mid and rear side rail brackets using supplied M6 screws. Fit the two front datum brackets to the side rail using the M6 shoulder bolts and spacers.
  • Page 51 EGR ROLLTRAC ASSEMBLY Step Instruction Image...

  • Page 52: Knowledge Check & Observation

    EGR RollTrac Training Manual - JEEP Gladiator 2020+ KNOWLEDGE CHECK & OBSERVATION - EGR ROLLTRAC ASSEMBLY What are the two (2) things you can do to make attaching the side rails easier? Answer If correct, Trainer to Tick What must be disengaged before commencing EGR RollTrac...
  • Page 53 KNOWLEDGE CHECK & OBSERVATION - EGR ROLLTRAC ASSEMBLY What is critical during side rail attachment and why? Answer If correct, Trainer to Tick What must be installed correctly to ensure a weather tight seal? Answer If correct, Trainer to Tick...
  • Page 54 Competent Competent EGR ROLLTRAC ASSEMBLY Has the installer safely placed the EGR RollTrac on two (2) boxes or other cleaned assembly area? Has the installer untied wiring loom from side rails? Did the installer direct the wire through the groove?
  • Page 55 EGR ROLLTRAC ASSEMBLY OBSERVATION Not Yet TASK Competent Competent EGR ROLLTRAC ASSEMBLY Has the installer refitted the three (3) screws and torqued them to 5.5 Nm? Did the installer turn the assembly over and secure the side rails with the two (2) extra screws?

  • Page 56: Egr Rolltrac Installation (Section D)

    EGR RollTrac Training Manual - JEEP Gladiator 2020+ EGR ROLLTRAC INSTALLATION Step You may need to lift the Left Hand Side of the cover and use packer to aid Instruction Image • connection. • Ensure you centralise and align the cover to the markings.
  • Page 57 Trim the tube at the indicated ridge. Connect the rear drain tubes to the RollTrac and secure them with cable ties, and connect the front drain tubes to the bed.
  • Page 58 EGR RollTrac Training Manual - JEEP Gladiator 2020+ EGR ROLLTRAC INSTALLATION Step Instruction Image Apply masking tape at the centre of the tailgate. Using a tape measure and pen, measure the distance between the rear corners of the bed and mark a centre line on the masking tape.
  • Page 59 EGR ROLLTRAC INSTALLATION Step Instruction Image Secure the rear and middle RollTrac brackets to the mounting brackets in the bed. Using a torque wrench, tighten the bed bracket bolts 9 Nm or 6.63 foot pounds. Followed by the RollTrac bracket bolts.
  • Page 60 EGR RollTrac Training Manual - JEEP Gladiator 2020+ EGR ROLLTRAC INSTALLATION OBSERVATION Not Yet TASK Competent Competent EGR ROLLTRAC INSTALLATION Has the installer marked the tailgate rail using masking tape to identify positions for drilling rail mounting holes? Has the installer used a straight edge and masking tape to mark...

  • Page 62: Lubrication Of Spirals

    Step Instruction Open the tailgate. Open both inspection covers. Close the EGR RollTrac manually – ensure that motor clutch is disengaged. Spray silicone spray onto the spirals on both sides of the canister. Inspect all drainage tubes and ensure they are secured correctly and not kinked or bent.
  • Page 63 EGR ROLLTRAC INSTALLATION Has the installer opened the tailgate and inspection covers? Has the installer disengaged the motor clutch of the EGR RollTrac? Has the installer closed the EGR RollTrac manually? Did the installer spray the spirals with silicone spray?
  • Page 64 EGR RollTrac Training Manual - JEEP Gladiator 2020+ CALIBRATION, OPENING, CLOSING AND LOCKING PROCEDURE Step Instruction Video Insert Watch the following video on Calibration QR code Calibration and Testing. here Scan the QR Code to begin the video. CALIBRATION, OPENING, CLOSING AND LOCKING PROCEDURE...
  • Page 65 • Press ‘unlock’ button on the car remote. • Press the front button on the EGR RollTrac side rail. • To lock press the rear button on the RollTrac side rail. • Press the ‘lock’ button on the car remote.
  • Page 66 • Check that it has locked by opening the tailgate, if lock does not engage, recheck cover installation. Emergency opening: The EGR RollTrac has an internal manual unlocking handle, test that it works by twisting the handle as indicated by the arrows and ensure that the latches move.

  • Page 67: Knowledge Check & Observation

    KNOWLEDGE CHECK & OBSERVATION - CALIBRATION & TESTING What needs to be engaged on the RollTrac before calibration can start? Answer If correct, Trainer to Tick What do you need to press and for how long to start the calibration mode?
  • Page 68 EGR RollTrac harness in the engine bay? Has the installer engaged motor clutch on the EGR Rolltrac? Has the installer inserted the fuse back to the EGR RollTrac harness while the engine is running? Did the installer press the two (2) side buttons simultaneously for 10...
  • Page 69 • Located clutch disengagement lever on the right-hand side of cover. • Pushed the clutch inwards to disengage the motor on the EGR RollTrac. • Pulled the cover forward and backwards as required. • Re-engage clutch in the RollTrac motor before driving car.

  • Page 70: Clean Up

    Dispose of any packaging and waste according to company procedures and policy. Complete the checklist in the Owner’s Manual for the EGR RollTrac. Clean the EGR RollTrac using multi – purpose cleaner to remove any residue from packaging and installation. CLEANING UP OBSERVATION Not Yet...

  • Page 71: Troubleshooting

    Manually lock and unlock using the key, recheck operation • Remove power (fuse) and wait for 5 sec. before applying power back to RollTrac and recalibrate. • Error mode is indicated by flashing LED lights and loss of function mid...
  • Page 72 EGR RollTrac Training Manual - JEEP Gladiator 2020+ TROUBLESHOOTING Fault Action EGR RollTrac • Prior to calibration check cover operates manually (check this by disengaging the emergency clutch release and manually opening is not running and closing cover), if cover does not operate check for mechanical...
  • Page 73 If Roll Cover is operational - Check connections to LED light in side rail are pushed home. • Check light operation in previous section of the Owner’s Manual. Switch on/off • If EGR RollTrac is not operational – lighting is linked to installation of vehicle harness and connectors, troubleshoot and recheck operation.
  • Page 74 EGR RollTrac Training Manual - JEEP Gladiator 2020+ TROUBLESHOOTING Fault Action Dust ingress in • From the factory vehicle beds have various openings (to allow for water drainage etc.). Ensure these openings are properly sealed to prevent dust ingress. •...

  • Page 75: Egr Trainer Sign - Off

    I, the person conducting the training, declare that the above-mentioned Candidate participated in the appropriate training of the EGR RollTrac installation for a Jeep Gladiator. The information recorded above is a true reflection of this Candidate’s skills. The Candidate has been provided with feedback and informed of the result and the reasons for the decision.

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