Pioneer Rack and Pinion Tarp Replacement

At American Tarping, we pride ourselves on being a family-owned and operated distributor dedicated to supplying premium-quality tarp systems at fair prices. Our commitment to customer service sets us apart in the truck tarp industry. One of our most popular solutions is the Pioneer Rack ’n Pinion® Roll Off Trailer System—especially the Pioneer RP4500SATR. Below, we’ll explore what makes Rack ’n Pinion technology exceptional and how to handle a “pioneer rack and pinion tarp replacement” step by step, based on best practices and industry insight.

Why Choose the Rack ’n Pinion® Roll Off Trailer Tarp System?

Pioneer’s Rack ’n Pinion® design has been an industry leader for over a decade. The “tombstone” emblem on each unit symbolizes its proven reliability and quality. Thanks to advanced hydraulic arms and gear assemblies, along with “Strong Arm” technology, you get a controlled and efficient tarp deployment every time.

Pioneer RP4500SATR – Strong Arm Roll Off Trailer Tarp System

• Rack and Pinion Technology: A hydraulic cylinder moves a rack gear forward and backward. The rack gear meshes with a pinion gear at the pivot arm base, creating a mechanical advantage that delivers stable, synchronized arm movement.
  
  

• Heavy Duty Mesh Tarp: The system comes standard with a 114-inch-wide heavy duty mesh tarp, perfect for effectively covering open-top containers.
  
  

• Application: Ideal for cable hoist roll off trailers handling up to 32-foot containers in length.
  
  

• Tarping Precision: The pivot assembly, powered by the hydraulic rack and pinion, provides continuous control over speed and precise synchronization of the arms—reducing the risk of tarp damage.
  
  

Look for the Rack ’n Pinion® tombstone to confirm you have a genuine Pioneer system with best-in-class performance.

Pioneer Rack ’n Pinion® Roll Off Container Systems: RP4500SAR & RP4500SARG

Aside from the RP4500SATR tailored for up to 32-foot containers, Pioneer also offers:

• RP4500SAR (Fixed Gantry)
  
  

• RP4500SARG (Telescoping Gantry)
  
  

These versions cater to containers up to 24 feet in length and come standard with a 114-inch-wide heavy duty mesh tarp. They share many of the same proven design elements:

• Reinforced “C” Channel Arms: Greater control, extended operational life, and minimal maintenance.
  
  

• External Cylinders: Easier to access and maintain.
  
  

• Everlast Roller Assembly: Spring-loaded to keep the tarp taut and reduce wear.
  
  

• Offset Stabilizer Bar: Protects the roller from damage.
  
  

• Non-Prorated 5-Year Warranty: Demonstrates Pioneer’s confidence in their Rack ’n Pinion® technology.
  
  

Whether you choose the RP4500SATR for longer containers or the RP4500SAR/SARG for shorter ones, each system is engineered for reliable performance in demanding conditions.

Pioneer Rack and Pinion Tarp Replacement Tutorial

If you already own a Pioneer Rack ’n Pinion® system and need to replace a worn or damaged tarp, here is a general outline of the process. Always follow specific manufacturer guidelines and safety procedures. You can follow along here with images included for further description.

Step 1: Prepare the Tarp and Gather Materials
• Lay Out the Tarp: Spread the tarp on the floor with its reinforcement side facing down. Smooth it out so that it lies neatly, and separate it properly.
• Prepare the Shock Cords: Retrieve the three pieces of shock cord (bungee cord style) supplied with the tarp. These cords are essential for securing the tarp later on.
(See PDF, Step One)

Step 2: Identify the Tarp’s Loop Locations and Prepare for Tying
• Locate the Loops: On the top of the tarp, you will find three sets of loops. These loops serve as tie points for the shock cords.
• Arrange the Shock Cords: Plan to use one shock cord for each corresponding loop, arranging them from left to right as indicated in the PDF’s diagrams.
(See PDF, Step Two)

Step 3: Tie the First Edge Knot
• Select an Edge Loop: Choose one of the loops located at the tarp’s edge—either on the driver’s side or the passenger’s side (either side works equally well).
• Secure the Shock Cord: Tie a double or triple knot in the chosen edge loop to anchor one end of the shock cord securely.
(See PDF, Step Three)

Step 4: Thread the Center Loop
• Feed the Cord: Take the free end of the shock cord and pass it through the center loop of the tarp. This step is similar to threading a needle, ensuring that the cord runs cleanly through the loop.
(See PDF, Step Four)

Step 5: Tie Off the Final Loop and Attach the Tarp to the Roller
• Adjust Tension: With the cord threaded through the final loop, pull out the slack and add an extra 6 to 10 inches of tension. Tie a modest single knot—this allows for later adjustments if needed.
• Mount on the Roller: Once the shock cords are secured and the tarp displays the correct tension, attach the tarp to the roller. Insert bolts and washers through the tarp’s grommets, making sure that when installed, the tarp exits from the bottom of the roller.
(See PDF, Step Five)

Step 6: Start Winding the Tarp onto the Roller
• Begin the Process: Start rolling the tarp onto the roller. It’s highly recommended that one person stands on each side of the tarp to help fold the flaps neatly as the tarp winds.
• Aim for a Neat Roll: The goal is to achieve a roll that resembles a tidy paper towel roll—uniform, crisp, and with the flaps carefully tucked under.
(See PDF, Step Six)

Step 7: Ensure the Tarp Flaps Are Properly Folded
• Folding Under: As you continue to wind the tarp, consistently fold the flaps underneath. Although the tarp is 9 feet wide, it must be folded to a little over 8 feet wide so it fits correctly on the roller.
• Team Effort: More hands make for a neater installation—consider having multiple helpers keep the flaps aligned neatly throughout the process.
(See PDF, Step Seven)

Step 8: Complete the Rolling Process
• Finish Winding: Continue rolling the tarp until it is completely wound onto the roller. Maintain a steady fold of the flaps to ensure even tension and a professional finish.
• Double-Check Neatness: A consistent, neat roll will support proper operation when the tarp is deployed.
(See PDF, Step Eight)

Step 9: Finalize Installation and Adjust Tension
• Install the Roller: Once the tarp is fully wound, mount the roller onto its designated arms on the system.
• Fine-Tune Tension: With the roller installed, adjust the system by either adding or releasing a bit of tension in the shock cords as necessary. Run the arms a few times to allow the knots to settle, and then tighten them securely.
• Quick Winding Instructions: As a reminder, when viewed from the driver's side, wind the shaft (not the aluminum tube) for about 7 counterclockwise revolutions.
• Test Functionality: Ensure the flaps naturally fold over the side of the container when covering and neatly collapse when uncovering.
(See PDF, Step Nine and Quick Winding Roller Instructions)

Always follow any specific safety guidelines provided by Pioneer and use the recommended safety gear during the installation process. Regular maintenance checks will ensure the tarp system continues to operate smoothly.

Additional Tips:

• Buddy System: Having an extra set of hands during removal and installation helps avoid tarp damage and reduces risk of injury.
  
  

• Know When to Replace vs. Repair: Minor tears can sometimes be patched, but major damage or severely worn material calls for full replacement.
  
  

• Regular Inspections: Frequent checks for frayed edges, loose fasteners, or misalignment help you catch small problems before they become big headaches.
  
  

• Follow Manufacturer Guidelines: Always consult Pioneer’s official manual or support for model-specific instructions, torque settings, and safety warnings.

By using this methodical approach, you’ll maintain your system in top condition and reduce downtime. The pioneer rack mount (gear assembly) plays a critical role in ensuring a controlled, efficient roll-out and retraction every time.

Trust American Tarping for Your Tarping Needs

At American Tarping, we don’t just sell top-tier tarp systems—we back them with friendly service and expert guidance. Whether you need a brand-new Rack ’n Pinion® setup, a straightforward tarp replacement, or additional parts and motors, we’re here to help.

Contact American Tarping today to learn more about the Pioneer Rack ’n Pinion® Tarp Systems and how they can elevate your roll-off trailer or dump truck operations. We’re always ready to assist with replacement parts, new systems, or any other tarp-related questions you may have.

Ready to Upgrade or Replace Your Tarp?

Call us or visit our website to discover why so many operators trust American Tarping for their tarping solutions. Experience the difference our customer service, expertise, and competitive pricing can make for your fleet.

Watch this tutorial as well to find out more details on the pioneer rack and pinion tarp replacement!

Disclaimer: Always refer to Pioneer’s official manuals and safety guidelines when installing or servicing tarp systems. The information provided here is for general guidance and should not replace manufacturer instructions.