ROUND TOP RV SHELTER 94182 ASSEMBLY AND OPERATING INSTRUCTIONS Visit our website at: http://www.harborfreight.com Read this material before using this product. Failure to do so can result in serious injury. Save this manual. Copyright 2006 by Harbor Freight Tools. All rights reserved. No portion of this manual or any artwork contained herein may be reproduced in any shape or form without the express written consent of Harbor Freight Tools. Diagrams within this manual may not be drawn proportionally. Due to continuing improvements, actual product may differ slightly from the product described herein. Tools required for assembly and service may not be included. For technical questions or replacement parts, please call 1-800-444-3353. Revised Manual 09k
Specifications Cover Assembled Dimensions Frame Securing Hardware Weight Polyethylene, UV protected; ¼ (dia.) braided nylon rope, 1 (W) x 0.055 (T) woven straps (inside end of cover) 32 L x 14 W x 12 H Round steel tubing, 1-1/2 (dia.) x 0.055 wall thickness Steel Ratchets (tie down top straps); Elastic cord/ball ties 670 lbs. Save This Manual You will need the manual for the safety warnings and precautions, assembly instructions, operating and maintenance procedures, parts list and diagram. Keep your invoice with this manual. Write the invoice number on the inside of the front cover. Keep the manual and invoice in a safe and dry place for future reference. Safety Warnings and Precautions WARNING: When using this product, basic safety precautions should always be followed to reduce the risk of personal injury and damage to equipment. Read all instructions before using this product! 1. Keep work area clean. Cluttered areas invite injuries. 2. Observe work area conditions. Keep work area well lit. Avoid sharp edges when assembling. Assemble on a flat and leveled area. 3. Check for damaged parts. Before using this product, any part that appears damaged should be carefully checked to determine that it will perform its intended function. Check for any broken or damaged parts and any other conditions that may affect its operation. Replace or repair damaged or worn parts immediately. Check that any of the components are not cracked or have splits that could affect the function and performance. 4. Replacement parts and accessories. When servicing, use only identical replacement parts. Use of any other parts will void the warranty. 5. Always check hardware and assembled parts after assembling. All connections should be tight and hardware tightened. 6. Keep children away. Children must never be allowed in the work area. Do not let them play in or around the RV Shelter. 7. Dress Properly. Protective non skid footwear are recommended when setting up the RV Shelter. Wear restrictive hair covering to contain long hair. 8. Use eye protection. Always wear ANSI-approved impact safety goggles when setting up this product. 9. Do not overreach. Keep proper footing and balance at all times. Page 2
10. Do not try moving assembled RV Shelter. Do not lift the RV Shelter. 11. Six or more people are needed to assemble. 12. Do not place anything on top of RV Shelter. 13. Avoid harsh conditions. The RV Shelter could topple in strong winds causing damage to property and personal property. Disassemble if weather conditions become severe and could damage the RV Shelter. Harbor Freight Tools is not responsible for damage due to weather conditions and will not be held responsible for a RV Shelter exposed to and/or damaged by conditions such as high winds, heavy rain, snow or ice under any conditions. 14. You will need to remove the cover when you know that severe weather conditions are approaching. And if covered, frequently check the anchoring system to ensure stability of the RV Shelter. Proper anchoring is your responsibility. Warning: The warnings, cautions, and instructions discussed in this instruction manual cannot cover all possible conditions and situations that may occur. It must be understood by the operator that common sense and caution are factors which cannot be built into this product, but must be supplied by the operator. Unpacking When unpacking, check to make sure that all the parts are included. Refer to the Parts List and Assembly Drawing at the end of this manual. If any parts are missing or broken, please call Harbor Freight Tools at the number on the cover of this manual as soon as possible. Preparation 1. Select the location for the RV Shelter. Assembly Requirements: Foundation should be a concrete slab, concrete footings, pressuretreated timbers, or railroad ties. Foundation or pad area must extend at least six inches larger than the size of the RV Shelter. See examples below. RV Shelter Pad Dimensions SHELTER 15 3 Wide 33 6 Long If possible, pick a location for the RV Shelter that has a natural or man-made wind break (e.g., barn, house, hedge, hill, etc.). Level pad area and clear of all debris. Page 3
2. Acquire two pressure-treated wooden sill plates (not supplied) that are 2 (D) x 6 (W) x 33 (L). Eighteen Heavy duty Base Plates (5a and 5b) are supplied to connect the shelter elements. Connecting these Base Plates to the ground, however, must be done with hardware not supplied. 3. Acquire 72 lag bolts and flat washers (not supplied) with a minimum size of 3/8 (dia.) x 2 (L) for securing the Base Plates to the wooden sill plates. 4. If the wooden sill plates are to be mounted directly to a cement slab, special cement anchors with hardware (not supplied) must be acquired for this process. If mounting the wooden sill plates to cement footings, acquire cement footings and securing hardware (not supplied). If mounting the wooden sill plates to railroad ties, acquire 12 railroad ties and earth anchors (not supplied). 5. Bring the following tools (not supplied) to the assembly site: power drill, drill bits and socket drivers (for lag bolts and nuts), screwdrivers, and adjustable wrench. Make sure that at least six people are available to assemble this product. Layout Component Parts Place all parts boxes in the center of the shelter pad area. Open each parts box labeled A through D and group each type of part. If parts are not labeled, mark the part number on each item. Base Plate Mounting 1. Lay the two wooden sill plates parallel to each other on the shelter pad. 2. Place the four corner Base Plates (5a) at the end of the wooden sill plates with the flanges facing out from the opposing plate. 3. Place the 7 other Base Plates (5b) in-between, and equally spaced, from the corner Base Plates (5a). Do this on the other wooden sill plate as well. 4. Using four screws and washers (not supplied), attach the corner Base Plate (5a) to the end of the wooden sill plate as shown at the top-left of the next page. The inside edge of the Base Plate should be flush with the sill plate as shown at the top-right of the next page. It is recommended to mark drill holes, then drill 1/4 pilot holes to accept the 3/8 lag bolts. Page 4
(16) 5. Take a Purlin (7) and temporarily attach to the Base Plate (5a) using Long Bolt (11), extending the Purlin to the next unmounted Base Plate (5b). Outside View Purlin (7) Purlin (6) Base Plate (5b) Base Plate (5a) Sill Plate 6. Attach the other end of the Purlin (7) to the Base Plate (5b) using Long Bolt (11). This process determines the distance between Base Plates for mounting. 7. Align the Base Plate (5b) to the edge of the sill plate, and when aligned, mark drill holes for mounting. 8. Drill holes and mount Base Plate (5b) with four screws and washers. 9. Rotate Purlin (7) 180 degrees and use on the next Base Plate (5b). 10. Repeat steps 5 to 9 for the balance of the Base Plates on this sill plate. 11. Repeat steps 4 to 10 on the other sill plate. Attach Sill Plates to the Shelter Pad If mounting the sill plates to a cement pad, follow these steps: 1. Lay each sill plate along the length of the cement pad with a 14 foot, inside distance between the corner Base Plates (5a) posts. See page 5 illustration, bottom-right. The sill plates must have at least six inches cement pad exposed on the outside of each sill plate. See illustration on page 5, bottom-left. Cement Pad (Top View) Sill Plates Railroad Ties Dirt, Grass, or Gravel Pad (Top View) Page 5
2. Align one of the sill plates on the cement pad, and mark its location with a marker. Mark drilling locations on the sill plate in between all Base Plates (5a and 5b). 3. With the help of two others to hold the sill plate in place, drill mounting holes through it and into the concrete. Drill hole size will depend on the size of the cement lag bolts and hardware (not supplied). The desired quantity of cement bolts is dependant on their size. Ask a licensed contractor. 4. When all holes are drilled for one sill plate, securely mount the sill plate in place. 5. Realign the other sill plate to exactly 14 feet, inside distance, from each Base Plate (5a). 6. With the help of two others, hold the unmounted sill plate in place and measure the distance from each diagonal corner, Base Plate (5a) posts. See illustration on page 7. The distance must be exactly the same, this confirms that the base is square. Adjust the unmounted sill plate if necessary. When the exact location is determined, mark the sill plate location. 7. Repeat steps 3 and 4. If mounting the sill plates to concrete footings (not supplied), follow these steps: 1. Lay each sill plate along the length of the pad area with a 14 foot, center-to-center distance between the corner Base Plates (5a) post. See illustration on page 5, topright. 2. Mark the perimeter of each sill plate on the ground, and each (drilling) center point in between each Base Plate location. 3. Move the sill plates out of the way, and prepare the concrete footings. Either dig holes and pour fresh concrete with protruding 1/2 inch diameter studs (minimum); or place preset concrete footings of at least one foot diameter and one foot in depth. 4. Align the sill plates on the foot mounting hardware, and mark and drill holes. Do this on one sill plate only at this point. 5. Securely mount the sill plate to the concrete footings and hardware. 6. Align the other sill plate on the opposite foot mounting hardware and, with the help of two others, hold the unmounted sill plate in place and measure the distance from each diagonal corner, Base Plate (5a) posts. See illustration on page 7. The distance must be exactly the same. Adjust the unmounted sill plate if necessary. When the exact location is determined, mark and drill the mounting holes to align with the protruding concrete footing hardware, and securely mount the sill plate in place. Page 6
If mounting the sill plates to railroad ties (not supplied), follow these steps: 1. Lay each sill plate along the length of the pad area with a 14 foot, center-to-center distance between the corner Base Plates (5a) post. See illustration on page 6, topright. 2. Mark the perimeter of each sill plate on the ground, and each center point in between each Base Plate (drilling) location. 3. Move the sill plates out of the way, and lay the railroad ties end-to-end. See illustration on page 6, top-right. Secure the railroad ties to the ground with earth anchors (not supplied). 4. Align the sill plates on the railroad ties, and mark and drill holes. Do this on one sill plate only at this point. 5. Securely mount the sill plate to the railroad ties with 1/2 inch diameter (minimum) rust resistant screws (not supplied). 6. Align the other sill plate on the opposite railroad ties and, with the help of two others, hold the unmounted sill plate in place and measure the distance from each diagonal corner, Base Plate (5a) posts. The distance must be exactly the same. Adjust the unmounted sill plate if necessary. When the exact location is determined, mark and drill the mounting holes into the railroad ties. Top View Mounting Frame Tubes, Pipes, and Purlins During this part of the RV Shelter assembly, it will go faster if others help in the process. Also, refer to the Assembly Drawing and Parts List at the end of this manual for guidance. 1. Place the Straight Vertical Tubes (4) over 18 Base Plates (5a and 5b), and align the lower mounting holes. See illustration on page 8. (4) 2. Attach a Brace (9) and Front Purlin (6) to the first Straight Tube (4) at the Base Plate (5a), using Long Bolt (11) and Nut (12). (4) (6) (11) (7) (12) 3. Insert the tapered end of a Swaged Purlin (7) into the end of the Front Purlin (6) and secure using a Long Bolt (11) and Nut (12). Continue assembling Purlins in this way to the end of the structure, then attach a Brace (9) between the last Purlin (7) and Straight Tube (4), using a Long Bolt (11) and Nut (12). (9) (5a) (8) (6) (5b) (7) 4. Repeat steps 1 and 2 at the end of this row, and on the opposite sill plate assembly. Page 7
Note: In the entire assembly, all Bolts must be mounted from the outside-in, so that the Roof Tarp (15c) will not be damaged by the Bolt ends. 5. Assemble and secure three arches at a time. Refer to the illustration below. a. Lay out three Roof Curve Pipes (1), six Short Curve Pipes (2), and six Long Curve Pipes (3). b. Insert the Short Curve Pipes (2) into each end of the Roof Curve Pipes (1). Align screw holes and secure with Short Bolt (10) and Nut (12). c. Insert the Long Curve Pipes (3) into the Short Curve Pipes (2). Align screw holes. d. With the help of two other people, lift the completed arch and insert it into the Straight Vertical Tube (4) on each side. Do the same with the other two arches. e. Using a ladder to reach the arch, attach Front Purlin (6), then Purlin (7) under the arches using Long Bolts (11) and Nuts (12). Do this in three places. Securely tighten. 6. Repeat step 4, assembling the balance of the arches. 7. When the frame is completed, check all Nuts and Bolts for tightness. Tarp Placement and Tie Down 1. Place a protective cover on the ground to one side of the frame. 2. Unfold the Roof Tarp onto the protective cover with the eyelets next to the sill plate. The inside of the Roof Tarp should be facing up. Do not step on the Roof Tarp. Page 8
3. Weave the Rope (14) through each eyelet and around the Front Purlin (6), and the rest of the Purlins (7). Refer to the illustration on the top of the next page. When weaving, leave about 1/2 inch between the Roof Tarp and the bottom Purlins. 4. After weaving the Rope (14), tie down the Rope to the end Base Plates (5a). Caution: Take care not to tear the Roof Trap eyelets out of the skin. 5. Tie the other Ropes (14) to the center and end eyelets on the other side of the Roof Tarp. 6. Throw the ropes over the top of the frame to the other side. See illustration above. 7. With the help of two others, carefully pull the Roof Tarp over the frame. Keep the Roof Tarp centered on the frame while pulling it over. It may help to have others guide the feeding of the Roof Tarp from where it is lying. Caution: Do not tear the Roof Tarp. If the Roof Tarp catches on part of the frame, stop pulling the Ropes. Get on a ladder and undo the catch. If it happens to be a Bolt placed upside down, reverse the Bolt mounting before proceeding. 8. With the Roof Tarp completely over the frame, weave the Rope (14) through each eyelet and around the Front Purlin (6), and the rest of the Purlins (7). 9. After weaving the Rope (14), tie down the Rope to the end Base Plates (5a). Tie the Rope to the Base Plate (5a). 10. Attach the Split Door Panel (15a) to the front entrance of the RV Shelter using Ball Tie Downs (13) through each eyelet. (16) Page 9
11. Attach the Solid End Panel (15b) to the back of the RV Shelter using Ball Tie Downs (13) though each eyelet. 12. Attach the Ratchet Tie Down (16) to each corner Base Plate (5a). 13. At each corner of the Roof Tarp is a flat strap. Feed the flat strap through the front (and back) covers, into the Ratchet Tie Down (16) and begin to tighten the each Ratchet alternately, a little at a time. When this happens, the 6 inch roof skin flap will fold over the frame ends as shown below-left. Maintenance 1. Periodically hose down the Roof Tarp of all dirt. 2. Periodically check the tightness of all Nuts, Bolts, and Ropes. 3. If snow or debris starts to accumulate on the Roof Tarp, gently clean the tarp off using a broom from the outside to knock the snow off. Use a step ladder supported by an assistant to access the top of the Shelter. Never enter the RV shelter if it is covered in snow or heavy debris. 4. Remove the Roof Tarp and store if inclement weather conditions are expected. 5. When storing the Roof Tarp, make sure that it is completely dry to prevent mildew and rot. 6. When storing large items in the RV Shelter, remove the Split Door Panel (15a) first, to avoid damage to the Split Door Panel. Page 10
Parts List Part Description Dimensions Qty Box 1 Top Curved Tube Ø1.5 x64 1 / 4 x0.06 9 A 2 Short Cuved Tube Ø1.5 x40 x0.06 18 A 3 Long Curved Tube Ø1.5 x64 1 / 4 x0.06 18 A 4 Straight Tube Ø1.5 x63 1 / 4 x0.06 18 C 5a Corner Base Plate (with Tie Down) 6 x5 3 / 4 x4 1 / 4 4 D 5b Center Base Plate 6 x5 3 / 4 x4 1 / 4 14 D 6 Front Purlin Ø1.5 x84 1 / 4 x0.06 7 C 7 Swaged Purlin Ø1.5 x50 3 / 4 x0.06 49 41 in B, 8 in C 8 Swaged Brace Ø1.5 x40 x0.06 4 A 9 Brace Ø1.5 x40 x0.06 4 A 10 Short Bolt M8x2 22 D 11 Long Bolt M8x3 3 / 4 63 D 12 Nut M8 85 D 13 Ball Tie Down 62 D 14 Rope Ø 3 / 16 x52 5 D 15a Door Panel 1 D 15b Back Panel 1 D 15c Roof Tarp 1 D 16 Ratchet Tie Down (part of Corner Base Plate (5a) 4 D NOTE: Some parts are listed and shown for illustration purposes only and are not available individually as replacement parts. PLEASE READ THE FOLLOWING CAREFULLY THE MANUFACTURER AND/OR DISTRIBUTOR HAS PROVIDED THE PARTS DIAGRAM IN THIS MANUAL AS A REFERENCE TOOL ONLY. NEITHER THE MANUFACTURER NOR DISTRIBUTOR MAKES ANY REPRESENTATION OR WARRANTY OF ANY KIND TO THE BUYER THAT HE OR SHE IS QUALIFIED TO MAKE ANY REPAIRS TO THE PRODUCT OR THAT HE OR SHE IS QUALIFIED TO REPLACE ANY PARTS OF THE PRODUCT. IN FACT, THE MANUFACTURER AND/OR DISTRIBUTOR EXPRESSLY STATES THAT ALL REPAIRS AND PARTS REPLACEMENTS SHOULD BE UNDERTAKEN BY CERTIFIED AND LICENSED TECHNICIANS AND NOT BY THE BUYER. THE BUYER ASSUMES ALL RISK AND LIABILITY ARISING OUT OF HIS OR HER REPAIRS TO THE ORIGINAL PRODUCT OR REPLACEMENT PARTS THERETO, OR ARISING OUT OF HIS OR HER INSTALLATION OF REPLACEMENT PARTS THERETO. Page 11
Assembly Diagram Page 12