EGR ROLLTRAC RT040484E Manual

What's in the box

KIT CONTENTS - COMPONENT NUMBER AND QUANTITY

EGR RollTrac FITTING KIT IN BOX

EGR RollTrac FITTING KIT COMPONENTS IN BAGS

EGR RollTrac FITTING KIT ADDITIONAL ITEMS

TOOLS REQUIRED - NOT SUPPLIED IN KIT

BED PREPARATION

1. 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 discard the front utility rail. Retain the 5 Torx screws.
   
   Move the driver seat all the way forward, before disconnecting battery negative terminal.
   
2. Mark the position of the front drain tubes holes in the bed front panel and drill with repeat on the RHS. Clean all burrs and coat the exposed metal with a suitable rust preventative (not supplied). Fit front drain tubes (14).
   
3. Mark the position for the Vehicle Harness on the LHS of the tub. The distance is 60mm PCD from the drain tube hole.
   
4. Fit the front drain tubes to the tub.
   
5. Mark the position of the rear drain tubes holes in the bed rear panel and drill with Ø29mm (11/8") holesaw. RHS shown. Repeat on the LHS. Clean all burrs.
   
6. 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 to the existing harness inside the tail light cavity using 1 cable tie. Trim 200mm from the bottom of the drain tube. Refit Rear Tail Lamps.
   
7. Place the header bar (5) on top of the tub front panel, press down and secure with 3 Torx screws (removed in step 1). Torque to 5.5Nm.
   
8. Assemble the corner bracket to the rail using T-Nut (11), screw (6) and one Torx screw (removed in step 1) as shown on the RHS.
   

ELECTRICAL LOOM INSTALLATION

DISCONNECT CAR BATTERY NEGATIVE TERMINAL. FIT THE FUSE AT THE END OF 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.

HARNESS ROUTING OVERVIEW FOR PETROL VEHICLE

1. 
   Make sure fuses are not fitted before making connection. Feed the harness into the engine bay on the LHS along the fire wall from underneath the vehicle. Use draw wire first by pushing it down from the engine bay. Attach the two main harness terminals (A&B) using tape and pull gently into the engine bay. Connect the vehicle harness branch (A) to the battery positive terminal. Connect the vehicle harness negative branch (B) to the stud on chassis as hown next to the battery.
   
2. From underneath the vehicle, route the Vehicle Harness connector C&D 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.
   
3. Inside the vehicle (LH) side, lift the scuff plate to allow lifting the carpet under the seat in order to expose the rubber grommet in the floor. Remove and discard the grommet. Feed the vehicle harness branch (C) into the cabin. Pull the harness until the grommet on the harness is sited securely in the floor hole.
   
4. Lift the rear scuff plate. Remove the middle panel on the B-pillar as shown above.
   
   Remove the seatbelt bolt in order to remove the middle panel). Place the wiring under the scuff plate and run to the base of the B-pillar.
   
5. Locate the connector on the outside of the B-pillar and disconnect as shown.
   
6. Locate the B-pillar harness plug and select the X and Y wires from the factory wiring. Strip 0.5 inch to expose copper as shown. Feed the Rolltrac vehicle harness up to the exposed wires on the B-pillar.
   
7. Insert stripped wires from vehicle harness unit through the hole in the factory wiring and wrap around it tightly. Use needle nose pliers to clamp down on the connection. Wrap the wires with 3M super 33+ or equivelant electrical tape. Zip ties can be added for aditional security. Rewrap the harness back as it was originaly. Secure Rolltrac harness to the existing harness using zip ties and refit the trim panel and scuff plate. Important: secure the Rolltrac vehicle harness neatly under the scuff plate.
   
8. Refit the connector on the outside of the B-pillar as shown.
   
9. From underneath the vehicle, route the Vehicle Harness connector D 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.
   
10. Pull up the connector (C) into the truck bed into the previously drilled hole in the front LHS of the bed, until the rubber grommet sits firmly in the hole.
    
    use draw wire to pull up the connector.
    

EGR RollTrac ASSEMBLY

DURING ASSEMBLY PROCEDURE SUPPORT AT CENTER OF CANISTER ONLY, PLACE ON TOP AND BASE CARTON (OR SIMILAR), COVER WITH FOAM BLANKET. TO AVOID SCRATCHING POWDERCOATED SURFACES. DO NOT LOAD ELECTRICAL CONNECTORS OR MOTOR COVER.

1. 1 Place the canister (1) on two protected boxes as shown, ensure hand rail and slat ends are aligned. Tape up the seal on the Side Rail (3) as shown.
   
   Carefully align and slide the rail over the handrail endcap and canister endplate taking particular care to ensure that the siderails are slid straight and no undue force is applied to the electrical contact. Details in following steps.
   
2. Pull hand rail to expose 3 slats. Slide the RHS Rail over slat ends and onto endcap location pins. Align the holes and secure loosely with two screws (15). Do not tighten. Repeat for LHS Rail (4).
   DURING ASSEMBLY PROCEDURE SUPPORT AT CENTER OF CANISTER ONLY, PLACE ON TOP AND BASE CARTON (OR SIMILAR), COVER WITH FOAM BLANKET. TO AVOID SCRATCHING POWDERCOATED SURFACES.
   
3. Carefully turn the assembly over and place onto a protected surface. Remove the tape holding the rubber seal and check the seal position as shown. Repeat for LHS Rail.
   
4. Slide the Front Plate (2) over the canister and into the side rail channels ensuring that the foam side rail tape is pulled out of side rail and the small rubber corner seal on the RHS and LHS of the front plate are not damaged.
   
   Spray the front cover edge with soapy water to allow it to slide easily into the sides, twisting side rails outwards will also help.
   
5. While sliding the front cover ensure the cast connectors are align.
   
6. Using 3 screws (6), secure the Front Plate (2) to the Canister Assembly (1) and torque to 5.5Nm (4ft-lb).
   
7. Carefully flip the assembly over onto a flat protected surface which will not damage the cover or scratch the paint work. Install the 2 screws (6) on each side through the canister and side rail into front cover. Torque all screws in order shown to 5.5Nm (4ft-lb).
   
8. Clean powder coated surface first with alcohol spray. Trim foam tape length to ensure the end will butt against front cover seal - avoiding any gap. Peel the protective liner from the foam tape, adhere to the channel in the side rail, Press down firmly to secure. Repeat on RH side rail.
   
9. Connect side rail harness connectors to the connectors on the canister on the LHS and RHS. Connect the lamp connector as shown next to the motor on the RHS. Secure the harness to the canister using cable ties and pads as shown. Ensure all cables are retained to prevent pinching during installation.
   
10. Install the Rubber Perimeter Seal (16) into each side rail and ensure seal is firmly seated (note the seal orientation).
    
    do not stretch the seal while fitting.
    

EGR RollTrac INSTALLATION

1. Spray the top surface of the tub 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 tub. Before dropping onto the tub, place two cardboard packers to hold the RollTrac off the final position in tub to support electrical connection and to allow gentle final placement of RollTrac onto tub. Connect the vehicle harness to the ECU as shown. Drop the RollTrac straight onto tub. Connect the front drain tubes to the canister. Connect the rear drain tubes and secure with cable ties.
   
2. Apply masking tape at the centre of the tailgate. Measure the distance between the rear corners of the tub and draw a centre line on the masking tape. Measure the distance from the marked centre 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 tub.
   
3. Fit the side rail brackets (10&9) to the utility rail using T-nuts (11) and screws (12) as shown in 3 locations. Align the top holes in the bracket (9) with the holes in the side rail. Do not tighten the screws.
   
4. Perform diagonal fitment check.
   
5. Fit the side rail brackets to the base rails with two screws (12) as shown in top detail. Torque the screws following the sequence in the detail. Work from the rear to the front as shown.
   

SILICONE LUBRICATION TO THE SPIRALS

(MODELS MAY VARY, IMAGES FOR REFERENCE ONLY)

TOOLS REQUIRED:

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.
  

END OF CALIBRATION

OPENING AND CLOSING PROCEDURE

Electric Opening Procedure:

1. Press the front button on the EGR RollTrac side rail as shown.

Electric Closing Procedure:

1. Press the rear button on the EGR RollTrac side rail as shown.
   NOTE: EGR RollTrac should open and close smoothly. If cover does not lock or open correctly, please refer to the trouble shooting section in the Owners Manual. If the EGR RollTrac closing is slow, clean the siderails and ensure that no dirt or debris is inside the drive rail.

Manual Opening and Closing Procedure:
Locate the Clutch Disengagement Lever on the RH side of the cover and push the Clutch inward to disengage the motor. Pull the cover rearward or forward as required. Before driving vehicle ensure you re-engage the clutch.

If clutch was disengaged, calibration procedure needs to be re-run prior to electric operation.

KEY FOB OPERATION

We recommend that you program your key fob to lock and unlock all doors using one click only. This function can be set on your infotainment screen using the vehicle system control function/setup:

LOCKING / AUTO CLOSE PROCEDURE

UNLOCKING / AUTO OPEN PROCEDURE

Safety

Documents / Resources

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