EGR ROLLTRAC, RT040032E Manual

UNPACKING

KIT CONTENTS - COMPONENT NUMBER AND QUANTITY

EGR RollTrac M-Bar Assy Hardware Kit

EGR RollTrac FITTING KIT IN BOX

SETTING BRACE

EGR RollTrac FITTING KIT COMPONENTS IN BAGS

EGR RollTrac FITTING KIT ADDITIONAL ITEMS

TOOLS REQUIRED - NOT SUPPLIED IN KIT

GLOSSARY:
Number inside a square indicate part number
Number inside circle indicate the sequence within a step
Number inside the hexagon indicate torque instruction

BED PREPARATION

1. Carefully remove any accessories (Sports Bars, Cabin Guards, etc.) attached to the bed of the vehicle. Thoroughly wash the vehicle and bed and ensure that all dirt and grease is removed. Allow to dry. Clean the top surfaces of the bed and tailgate and allow to dry. Carefully remove both Rear Tail Lamps with the appropriate tools and store in safe place. Retain all hardware for re-installation.
   
   Remove and retain Tie Down Hooks with mounting plates. Discard the screws.
   
2. On the front LHS of the bed, mark the position for the Main Harness grommet and drill with Ø29mm (11/8") holesaw. Clean all burrs and coat the exposed metal with a suitable rust preventative (not supplied).
   
3. Mark the position of the front drain tubes holes in the bed front panel and drill with Ø38mm (11/2") holesaw. LHS shown, repeat on the RHS. Clean all burrs and coat the exposed metal with a suitable rust preventative (not supplied). Fit front drain tubes (14).
   
4. Mark the position of the rear drain tubes holes in the bed rear panel and drill with Ø29mm (11/8") holesaw. LHS shown, repeat on the RHS. Clean all burrs and coat the exposed metal with a suitable rust preventative (not supplied).
   
5. Feed the rear drain tube into the drilled hole. Guide the plastic tube inside the tail light cavity towards the ground. Push the rubber tube in until it sits firmly in the hole as shown. Secure the drain tube (13) to the existing harness inside the tail light cavity using 2 cable ties (18). Refit Rear Tail Lamps.
   
6. Clean the front top of the bed using Isopropyl Alcohol/Water mix and apply primer to the top area. Allow to dry. Place the extrusion (19) on front of the vehicle bed, check the length and trim to full width if required. Pre-peel 50mm (2˝) of the tape liner from one end of the Rubber Extrusion (19). Place the Rubber Extrusion on top of the bed as shown and centralise. Once in position, peel the liner and apply firm pressure from the top. Silicone the gap between the panels as shown on both sides.
   NOTE: Holes in the bed should be sealed with Silicone to prevent dust and water ingress as required.
   
7. Check if the plastic spacers are in place, if they have fallen out during transport, please refit.
   
8. Check if the plastic spacers are in place, if they have fallen out during transport, please refit.
   
9. Fit the side brackets (7) to the mount extrusion (6) as shown. Do not torque the screws at this stage.
   Attention: Fit screws only two rotations into the plates.
   
10. Fit the side brackets (7) to the mount extrusion (5) as shown. Do not torque the screws at this stage.
    Attention: Fit screws only two rotations into the plates.
    
11. Fit the mounting bar assembly onto the vehicle bed, by moving it up vertically until the clamps grab the lip of the bed as shown in the section view.
    
12. Note: Trucks without factory supplied cargo hooks may need to be threaded/tapped M6xPitch: 1.0 Hold the assembly in position and fit screws (12). Do not torque the screws.
    
13. Fit the setup jigs, to set up the RH mount extrusion first. Adjust the mount extrusion front position to the bed cap and rear position to the top of the tailgate using the setup jigs as a guide.
    
14. Set front/back position of the mount extrusion relative to the tailgate 10mm(0.4'') gap as shown in top view. Set the vertical position of mounting extrusion by adjusting the extrusion relative to the bedcap (ensuring parts are held level). Use the setup jigs to achieve a 2.8mm(0.1'') step between the front end of the extrusion Vs bedcap; and a 2.8mm(0.1'') step between the rear end of extrusion Vs tailgate - as shown in detail views above.
    
15. Torque all screws to 5.5Nm(4ft-lb) in order shown above. Recheck mounting extrusion position from step 13 and remove setup jigs. Repeat step 10-14 on LH side.
    

ELECTRICAL LOOM INSTALLATION

WHILE ROUTING THE VEHICLE HARNESS AVOID ANY VEHICLE COMPONENTS THAT HEAT UP, SUCH AS EXHAUST AND ENGINE COMPONENTS. DO NOT ATTACH HARNESS TO MOVING PARTS, FUEL LINES, BRAKE LINES, MOVING PARTS AND AVOID PINCH POINTS. ENSURE VEHICLE PARTS ARE AT AMBIENT TEMPERATURE BEFORE PERFORM- ING FITMENT.

HARNESS ROUTING OVERVIEW

1. Remove the RHS front scuff plate as shown.
   
2. Remove the RHS B-pillar trim cover as shown.
   
3. Locate the connector on the outside of the B-pillar and disconnect as shown.
   
4. Locate the rubber floor plug on the front RHS of the vehicle as shown. Remove the plug and feed the B-connector from the main harness to the inside of the cabin.
   
5. On the front RHS lift up the carpet and pull in the vehicle harness connector B inside the foot well until the rubber grommet on the harness is secured in the floor hole. Feed the harness towards the rear to the B-pillar as shown.
   
6. Inside the vehicle connect the previously disconnected connector inside the B-pillar to the (E) connector from the T-patch. Feed the T-patch connector F to the outside of the B-pillar and connect to the previously disconnected harness in step 3 as shown in detail.
   
   FOR 2018-19 VEHICLES (INCLUDING RAPTOR) FEMALE CONNECTOR ON THE T-PATCH (E) NEEDS TO BE MODIFIED TO FIT THE VEHICLE HARNESS CONNECTOR (SEE DETAIL)
   
7. Run the harness connector (B) along the floor and up to the T-Patch and connect to the (G) connector joining T-patch and Rolltrac harness as shown.
   
   Secure the harness by using cable ties to the original vehicle harness and panel clip cable tie to the body on the B-pillar to keep away from the seat belt retractor. Test seat belt before and after refitting the panels. Refit the middle panel and kick panel with the scuff plate to the vehicle.
   
8. From underneath the vehicle, route the Vehicle Harness terminals (D&C) towards the front of the vehicle, following outside the chassis rail. Use the supplied cable ties and retain the vehicle harness every 200mm (8'') to the chassis rail using holes already present on the chassis rail.
   

F150 GAS ONLY MODEL BATTERY CONNECTION STEPS

9. Feed the harness into the engine bay along the RHS fire wall from underneath the vehicle. Use draw wire first by pushing it down from the engine bay behind the fuse box as shown. Attach the two main harness terminals (D&C) using tape and pull gently into the engine bay.
   
   Make sure fuses are not fitted before making connection.
   
10. Connect the vehicle harness branch (C) to vehicle body negative ground, located in the engine bay as shown. Once it is positioned, secure in place using cable ties. Connect the vehicle harness branch (D) to the positive terminal of the battery. Once it is positioned, secure in place using cable ties.
    NOTE: ensure fuses are not fitted to the harness.
    

F150 LIGHTING EV MODEL BATTERY CONNECTION STEPS

1. Remove front drivers side panel. All fixings can be released without the use of tools as shown.
   
2. In the trunk, remove the battery cover to gain access to the positive terminal.
   
3. Feed the harness into the trunk along the RHS fire wall from underneath the vehicle. Use draw wire first by pushing it down from the trunk. Attach the harness terminals (D) using tape and pull gently into the trunk. Run the harness along the top towards the battery as shown.
   
   Make sure the fuse is not fitted before making final connection.
   
4. Connect the vehicle harness branch (D) to the positive terminal of the battery. Once it is positioned, secure in place using cable ties.
   NOTE: ensure the fuse is not fitted to the harness.
   

11. From underneath the vehicle, route the Vehicle Harness connector A towards the rear of the vehicle, following outside the chassis rail. Use the supplied cable ties and retain the harness every 200mm (8'') to the chassis rail using holes already present on the chassis rail.
    
12. From underneath the vehicle, route the Vehicle Harness connector A towards the rear of the vehicle, following outside the chassis rail. Use the supplied cable ties and retain the harness every 200mm (8'') to the chassis rail using holes already present on the chassis rail.
    
13. Run the vehicle harness to the cross beam as shown in detail (1). Use long zip tie to secure it. Follow the cross beam to the other side of the vehicle. Keep the harness on top of the beam and away from the muffler and moving parts. Zip tie near the muffler as shown in detail (2). Near the fuel tank secure to the existing harness (3). At the end of the cross beam, use long zip tie and small one as shown in detail (4).
    
14. After securing the harness, pull up the connector (A) between the cabin and the truck bed into the previously drilled hole in the front LHS of the bed, until the rubber grommet sits firmly in the hole.
    

SETTING BRACE - USER GUIDE

• NOT TO BE USED AS LIFTING DEVICE
• MEASUREMENTS ARE STILL REQUIRED AS PER THE FITTING INSTRUCTIONS
• SETTING BRACE SHOULD BE REMOVED ONLY WHEN SET UP IS COMPLETED

1. Setting Brace comes pre-assembled. Fit the T-Nuts with washers and wing screws as shown to both ends of the Setting Brace. Place the Setting Brace over the rear of the Rolltrac and slide the T-Nuts into the slots as shown. Once in position, slide the brace backwards till the plastic part of the brace comes to contact with the edge of the rear End Cap.
   NOTE: Brace is equipped with locators at the bottom and those must be fitted into the side rails. Tighten the wing bolt (finger tight only).
   

EGR RollTrac INSTALLATION

1. Spray the top surface of the bed liberally with a soapy water solution to enable the Cover to slide easily. Using two people to lift the cover from both sides and carefully lower it onto the bed. Connect the vehicle harness to the ECU as shown.
   NOTE: You may have to lift the LHS of the cover and use packer to aid connection. Ensure all seals are sitting vertically as illustrated.
   
2. Apply masking tape at the center of the tailgate and each end to mark length. Measure the distance between the rear corners of the bed and draw a center line on the masking tape. Measure the distance from the marked center line to both rear corners of the RollTrac and ensure it is equally distanced. Adjust the cover so that it is aligned with the markings as shown. Ensure seals are not deformed by lifting cover and dropping vertically on bed.
   
3. Secure the rear of the Rolltrac side rail to the mount extrusion with one screws (17) on each side as shown. Secure the side rail with 7 screws (16) on each side. Work from RHS to LHS to avoid one side lifting up.
   NOTE: M6 metal plates inside the side rail can be moved to line up with holes, before fitting screws. Do not tighten yet.
   
   Check the clearance between rear corner casting and top of tailgate, target is 8mm.
   
4. Perform width check (using canister end as reference) and diagonal fitment check (mounting bolts may need loosening for adjustment). Open and close the cover by hand, checking for smooth operation and consistent 1.5-2.0mm(0.05-0.07") side to side free-play of slat assembly within side rails. If there are any tight spots, then check side rail position and re-adjust side rail width as required.
   
5. Working from RHS to LHS (to avoid one side lifting up) torque all screws to 5.5Nm (4ft-lb). Perform final fitment check as per step 4.
   
   Check the clearance between rear corner casting and top of tailgate, target is 8mm. Open and close the tailgate to check function of seal (makes contact with tailgate and does not over compress) if position requires adjustment refer to steps 12-14.
   
6. Connect the front drain tubes to the canister. Connect the rear drain tubes to side rails and secure with cable ties.
   

1. Open tailgate and EGR RollTrac
   
   
2. Using a 2.5mm Allen Key remove the 4 screws and open the inspection covers.
   
   Keep clear of moving parts and avoid unnecessary operation of the EGR RollTrac while inspection covers are open.
   
3. Close the EGR RollTrac to access canister internals
   
4. To avoid water leaks, look into the inspection points and check that the flanges of both front drain tubes are correctly engaged to the canister cover (without any kinking etc.), readjust if required.
   
5. Using plastic compatible 100% Silicone Spray (ONLY) spray onto the spirals on both ends of the canister through the inspection points.
   
6. Open the EGR RollTrac
   
7. Close the inspection covers and secure with retained screws. Open and close the EGR RollTrac to distribute lubricant and check operation.
   

CALIBRATION PROCEDURE

1. Insert fuse to EGR RollTrac harness.
   
2. Make sure the tailgate is closed.
   
3. Engage motor, pull out lever (clutch).
   
4. Make sure the vehicle is unlocked and driver door open.
5. Press both buttons and hold for 5 sec. until light illuminates.
   

Keep obstructions clear of cover during calibration mode.

• Cover will CLOSE and OPEN once automatically.
• The EGR RollTrac internal LED light will pulse slowly during calibration and stop pulsing when calibration is complete.

OPENING AND CLOSING PROCEDURE

Safety

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