Aero Easy Cover Installation Instructions Manual Download Page 2

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Easy Cover

Installation Directory

Item Step

Page

Safety Information

Warranty Information and Tools Required

End Plates, Wind Deflectors, and Tarp Housing
Installing End Plates and Wind Deflector

Installing Tarp Housing Inside Cab Shield

6-7

Installing Tarp Housing with Trailer Mounting Brackets

Roll-up Bar
Installing Manual Fixed Roll-up Bar

Installing Electric Motor and Fixed Roll-up Bar

Installing Manual Adjustable Roll-up Bar

Installing Electric Motor and Adjustable Roll-up Bar

Sprocket, Crank, Chain, and Chain Covers
Installing

Sprocket

Installing Manual Crank Assembly

Installing Chain and Chain Cover(s)

Electrical
Installing Standard Electrical Controls with Rocker Arm Switch

15-16

Install and Wire Motor for Semi-trailer Truck

Install Interior Cab Rocker Switch for Semi-trailer Truck

Wiring Diagram for Lead & Pup with Contactors Mounted on Tractor

19-20

Wiring Diagram for Lead & Pup with Contactors Mounted on Trail

Installing the Optional Electrical Controls with Rotary Switch

22-23

Spring Assemblies
Installing Undermount or Flange Mounted Spring Assembly

Installing Underbody Spring Assembly

Installing Undermount or Flange Mounted Spring Assembly

26-27

Installing PowerPack Spring Assembly

28-30

End Fittings & Lower Swing Arms
Installing End Fitting and Steel Lower Swing Arm

Installing End Fitting and Aluminum Lower Swing Arm

Installing Aluminum Lower Swing Arm on PowerPack Spring Assembly 6c

Cross Arm and Connecting Arms
Installing Steel Cross Arm and Connecting Arms

Installing Upper Swing Arms and Cross Arm

35-36

Attach Tarp to Roll-up Bar
Installing Tarp to Roll-up Bar, Roll Under (Standard)

Installing Tarp to Roll-up Bar, Roll Over (Optional)

Easy Cover

Electric Model

Operation

Instructions

Maintenance

Recommendations

Easy Cover

Manual Model

Operation

Instructions

Maintenance

Recommendations

Summary of Contents for Easy Cover

Page 1: ...dustries com Indianapolis IN Omaha NE Streetsboro OH Attention Dealers Please give this owners manual to the customer when the product is delivered Serving the Truck Trailer Industry Since 1944 Easy Cover Installation Instructions ...

Page 2: ... for Lead Pup with Contactors Mounted on Tractor 4d 19 20 Wiring Diagram for Lead Pup with Contactors Mounted on Trail 4e 21 Installing the Optional Electrical Controls with Rotary Switch 4f 22 23 Spring Assemblies Installing Undermount or Flange Mounted Spring Assembly 5a 24 Installing Underbody Spring Assembly 5b 25 Installing Undermount or Flange Mounted Spring Assembly 5c 26 27 Installing Powe...

Page 3: ...F CTOU VCTR Ä Ä Ä 06 0 0 05647 6 105 Refer to Maintenance sheet or website Repairs must ONLY be made after proper instruction Spring tension must be properly released before repairs Replace damaged or broken parts Keep path of arms clear 12 4 6 10 05647 6 105 Refer to Operations sheet or website Face vehicle into the wind Only drive with tarp in fully covered or uncovered position Routinely inspec...

Page 4: ...1 1 8 hole saw Drill Bits 257 F drill 9 32 316 O drill 13 32 17 32 Sockets 7 16 9 16 Open End or Box Wrenches 7 16 9 16 3 4 Vice Grip Pliers 2 pair Electric or Air Drill Tools Required for Installation This manual explains how to install and maintain the Easy Cover tarping system ...

Page 5: ...e against the cab shield or top rail Lift rear of assembly until the aligning notch is even with the top rail Clamp driver s side end plate into place 4 Using the end plate as a template drill three 13 32 holes through the top rail where square holes reside 5 Secure driver s side end plate with 3 8 16 x 1 hex bolt 5 3 8 lock washer 6 and 3 8 16 Nylon hex nut 7 6 Repeat Steps 4 and 5 for passenger ...

Page 6: ...o to get dimension C Turn tarp housing 1 upside down and position steel angle until dimension C is maintained on both ends and mark in center of slotted hole The slotted holes allow the tarp housing to be moved 1 2 once mounted to the left or right if measurements are not exact Drill marked holes using 17 32 drill bit Index Description Qty 1 Tarp Housing 1 2 Mounting Bracket 4 3 Rubber Bushing 4 I...

Page 7: ... 2 ﬂat washer 5 and 1 2 13 nylon hex nut 6 4 See Figure 5 Set housing with rubber bushings 3 onto mounting bracket 2 and fasten securely through slotted holes 1 2 13 x 2 hex bolt 4 1 2 ﬂat washer 5 and 1 2 13 nylon hex nut 6 Rubber bushings should compress to about 3 8 to 1 2 D S View Figure 5 1 2 3 8 1 2 1 2 5 6 5 6 4 3 4 ...

Page 8: ...ach mounting brackets with rubber bushings 3 1 2 13 x 2 hex bolt 4 1 2 ﬂat washer 5 and 1 2 13 nylon hex nut 6 Tighten until bushings compress to approximately 3 8 to 1 2 4 See Figure 7 Hold housing up to trailer ﬁrmly center on trailer and trace holes in mounting brackets Drill marked holes using 17 32 drill bit 5 Attach with 1 2 13 x 2 hex bolt 4 1 2 ﬂat washer 5 and 1 2 13 nylon hex nut 6 Index...

Page 9: ...ugh the bearing 3 Bolt the shaft using the 1 4 20 x 2 1 4 hex bolt and 1 4 20 nylon hex nut remove in step 1 4 On the passenger s side align the ﬁxed manual roll up bar 1 with the bearing and insert shaft through the bearing 5 Bolt the shaft using the 1 4 20 x 2 1 4 hex bolt and 1 4 20 nylon hex nut remove in step 1 Index Description Qty 1 Fixed Manual Roll Up Bar 1 Figure 8 1 4 20 x 2 1 4 Hex Bol...

Page 10: ... does not have a shaft Remove the nut and bolt from that end Insert end onto shaft of motor RA SWB 1 line up hole in roll up tube with hole in motor shaft and with previously removed nut and bolt secure roll up bar to shaft 6 On the opposite end line up the ﬁxed electric roll up bar 2 with the bearing and insert shaft through the bearing 7 Bolt the shaft using the 1 4 20 x 2 1 4 hex bolt and 1 4 2...

Page 11: ... sure driver s end of roll up bar is against bearing Extend other end of roll up bar out and insert shaft through the bearing on the passenger s end of tarp housing 4 See Figure 11 With passenger s end of roll up bar within 1 4 1 2 of bearing drill two 257 F drill holes thru both tubes as shown 5 Secure outside tube to inside tube with two 1 4 x 2 1 4 Hex Bolts from hardware pack Index Description...

Page 12: ...r winch B line up hole in roll up bar with hole in motor shaft and with previously removed nut and bolt secure roll up bar to shaft 5 Extend other end of roll up bar out and insert shaft through the bearing on the passenger s end of tarp housing 6 With passenger s end of roll up bar within 1 4 1 2 of bearing drill two 257 F drill holes thru both tubes as shown 7 Secure outside tube to inside tube ...

Page 13: ... 1 Remove the cover if installed on the crank assembly and lay cover aside until after the chain is installed 2 See Figure 14 Place the crank assembly at or near the bottom front corner of the box on the driver s side Rotate the crank assembly so that it angles toward the tarp roll up bar 3 Mark the mounting holes on the box Drill marked holes using 13 32 drill bit 4 Fasten the crank assembly to t...

Page 14: ...Brackets 6 6 14 x 1 2 Self Drilling Screw 6 7 14 x 1 Self Drilling Screw 6 8 Crank Handle 1 Figure 15 Aluminum Cover 3 See Figure 16 Install crank cover lower aluminum 4 with the guard mounting brackets 5 to the body with 14 x 1 2 self drilling screws 6 and 14 x 1 self drilling screw 7 4 See Figure 17 Position the chain cover aluminum 3 so that it lays over the top edge of crank cover lower alumin...

Page 15: ... Nut 4 19 5 16 Lock Washer 4 20 Clamp Metal Loom Plastic Coated 12 21 Wiring Diagram Reverse Contactor 1 CVV VT 4GX VT YF 6 6 8 CVVGT 2QUKVKXG 4QEMGT 5YKVEJ 0GICVKXG CVV Ä Figure 18 1 Open and layout all electric hardware parts 2 Find a convenient place on the driver s side under the dashboard to mount the rocker switch Using the switch as a template mark and drill two 9 32 holes 3 Mount rocker sw...

Page 16: ...eration Insufﬁcient or improper loop can result in wire damage when the bed is raised 7 Measure distance between rocker switch 3 and reverse DC contactor 1 Wire switch 3 and reversing DC contactor 1 according to diagram with 14 wire 6 8 Measure distance between battery and reverse DC contactor 1 run 6 wire 5 between the two 9 Install a circuit breaker 4 at or very near the battery s positive termi...

Page 17: ...to the front of the trailer and up to the motor Secure all wire with clamps For Bottom Dumps 2b See Figure 21 Run 6 wire from receptacle up to the motor Secure all wire with clamps Figure 20 CWIG 9KTG QVQT 2TQPI 2NWI CWIG 9KTG 4QEMGT 5YKVEJ 4GXGTUKPI QPVCEVQT Figure 21 QVQT 2TQPI 2NWI CWIG 9KTG 4QEMGT 5YKVEJ 4GXGTUKPI QPVCEVQT CWIG 9KTG 3 Attach 6 wire to motor with 1 4 ring terminals 6 Black Wire...

Page 18: ... 4 20 x 2 hex bolts 4 Connect breaker to battery and secure with zip ties 3 Run wire from switch to reversing contactor Run wire from battery to reversing contactor Secure all wire with clamps 5 Connect receptacle to reversing contactor Make sure to have enough wire to be able to plug into trailer 6 Place cover on reversing contactor 7 Test switch to see if system operates correct direction If not...

Page 19: ...ty 11 Wire End 14 x 3 8 Ring Term 2 12 Plug Quick Disconnect Assembly 2 13 10 32 Hex Nut 2 14 1 4 20 x 1 Hex Head Bolt 4 15 1 4 20 x 2 Hex Head Bolt 4 16 1 4 Flat Washer 16 17 1 4 20 Nylon Hex Jam Nut 8 18 5 16 24 Hex Nut 8 19 5 16 Lock Washer 8 20 Wiring Diagram Reverse Contactor 1 Figure 22 1 2 3 4 12 6 7 8 10 8 13 9 6 2 1 5 8 5 5 5 5 10 7 8 12 8 8 8 8 8 8 10 10 10 10 Positive Negative Battery 1...

Page 20: ...s Figure 23 5 146 17 9 4 0 4 272 9 4 0 4 QVQT 2TQPI 2 2NWI 9KTG 9KTG 4QEMGT 5YKVEJGU CVVGT 2TQPI 2 2NWD 5RNKEG 4GXGTUKPI QPVCEVQTU QVQT 2TQPI 2 2NWI 2TQPI 2 2NWI 2TQPI 2 2NWI QVQT QVQT 2TQPI 2 2NWI 4QEMGT 5YKVEJGU CVVGT 4GXGTUKPI QPVCEVQTU ...

Page 21: ...lug Quick Disconnect Assembly 2 12 Plug Quick Disconnect Assembly 2 13 10 32 Hex Nut 4 14 1 4 20 x 1 Hex Head Bolt 4 15 1 4 20 x 2 Hex Head Bolt 4 16 1 4 Flat Washer 16 17 1 4 20 Nylon Hex Jam Nut 8 18 5 16 24 Hex Nut 8 19 5 16 Lock Washer 8 20 Wiring Diagram Reverse Contactor 1 Step 4e Wiring Diagram for Lead Pup with Contactors Mounted on Trailer 1 2 3 4 11 6 6 7 8 10 8 13 9 6 2 1 5 8 6 5 5 5 10...

Page 22: ...ips 12 12 1 4 20 x 3 4 Hex Head Bolt 2 13 1 4 Flat Washer 4 14 1 4 20 Nylon Hex Nut 2 15 Wiring Diagram 1 Gearmotor Wire End 2 1 4 x 6 Plate B2 Switch Switch Rotary Battery Truck A2 B1 A1 B1 B2 A2 A1 Backview of Rotary Switch Figure 25 3 Mount a weather proof box outside the cab and mount the rotary switch 1 inside the box Using the mounting bracket 3 as a template mark and drill two 9 32 holes 4 ...

Page 23: ...At the rotary switch fasten 6 x 10 ring terminals 8 to the ends of wires A1 and A2 at the switch attach these two ring terminals to the marked terminals of rotary switch 10 Measure the wiring distance between the rotary switch and truck s battery If possible run the wiring along an existing wiring harness Run wiring to truck s Battery 13 Fasten 6 x 10 ring terminals 8 to the ends of wires B1 and B...

Page 24: ...oth sides 4 Position the driver s side spring assembly 1 to the point marked on the driver s side B Clamp the spring assembly into position centering the mounting plate on point B The top of the mounting plate should be as high as possible from the bottom of the box 5 See Figure 29 Drill four 13 32 holes using the mounting plate as a guide 6 Bolt the spring assembly to the box or rail with 3 8 16 ...

Page 25: ...Figure 31 Place spring assembly housing up underneath dump body aligned at point B Rest the top edge against the bottom of the dump body Once in place trace the holes onto the dump body 6 Drill four 13 32 holes and the 1 1 8 hole with a hole saw 7 See Figure 32 Bolt spring assembly housing to the dump body using 3 8 16 x 1 hex bolt 3 3 8 ﬂat washer 4 and 3 8 16 nylon hex nut 5 If optional plate al...

Page 26: ...o install the spring assembly Figure 33 Use mounting holes to mark the hole location Repeat for opposite side of trailer Using a 9 16 drill bit drill the mounting holes Repeat for opposite side of trailer STEP 2 Marking the pilot holes STEP 3 Drilling the mounting holes 9 16 drill bit Marker Mounting holes Point B Mark and drill both Driver Side and Passenger Side holes ...

Page 27: ...ver Installation Instructions STEP 4 Mount the spring assembly Optional Rear Mounting Plate Lock Nut Flat Washer Lock Nut Hex Bolt Flat Washer Flat Washer Dump Body STEP 5 Attach the Optional Rear Mounting Plate ...

Page 28: ...t hole Marker Point B Use pilot holes to mark the hole location Repeat for opposite side of trailer Using a 9 16 drill bit drill the mounting holes Repeat for opposite side of trailer Mark and drill both Driver Side and Passenger Side holes STEP 2 Marking the pilot holes STEP 3 Drilling the mounting holes 9 16 drill bit 5 57 4 03 5 50 14 53 3 50 86 5 50 P 56 ...

Page 29: ...3 nylon hex nuts Driver Side of Dump Body Front Tailgate On the passenger side rotate the mounting bracket to the position shown and attach using the 1 2 13 X 2 bolts 1 2 ﬂat washers and 1 2 13 nylon hex nuts STEP 4 Installing Drive Side Mounting Bracket Index Description Qty 1 Mounting Brackets 2 2 1 2 13 x 2 Hex Bolt 4 3 1 2 Flat Washer 4 4 1 2 13 Nylon Hex Nut 4 STEP 5 Installing Passenger Side...

Page 30: ...On the mounting bracket shaft place in this order Description Qty 9 1 1 4 Flat Washer 1 5 PowerPack Casting half 1 8 Plastic Insert B 1 6 Spring PowerPack Spiral 3 7 Plastic Insert A 1 5 PowerPack Casting half 1 9 1 1 4 Flat Washer 1 10 1 1 4 External Retaining Ring 1 STEP 7 Assemble and install the Passenger Side PowerPack spring Tailgate 5 9 9 10 7 6 5 8 Front Driver Side of Dump Body A Neck Spr...

Page 31: ...m nut 5 2 See Figure 39 Place a end ﬁtting 1 on the driver s side tension spring assembly shaft so it is facing the rear 3 See Figure 39 Drive 1 4 spring pins 2 into the end ﬁtting 1 and thru the shaft 4 Repeat for opposite side Figure 39 5 2 4 1 3 Index Description Qty 1 End Fitting 1 2 1 4 Spring Pins 4 3 Swing Arm Lower Steel 2 4 5 16 18 x 2 1 4 Hex Bolt 4 5 5 16 18 Nylon Hex Jam Nut 4 Facing D...

Page 32: ...acing the rear See Figure 42 2 See Figure 41 Drive 1 4 spring pins 2 into the end ﬁtting 1 and thru the shaft 4 Repeat for opposite side 5 See Figure 41 Place swing arm lower aluminum 3 onto casting and secure with 5 16 18 x 1 HWH Type F 4 Index Description Qty 1 End Fitting 1 2 1 4 Spring Pins 4 3 Swing Arm Lower Aluminum 2 4 5 16 18 x 2 HWH Type F 4 4 2 3 1 Figure 41 Facing Down Facing Up Figure...

Page 33: ...rPack Spring Assembly 1 See Figure 43 Slide swing arm lower aluminum 1 onto powerpack spring assembly 2 See Figure 43 Secure with 3 8 16 x 2 HWH type F 2 3 Repeat for opposite side Index Description Qty 1 Swing Arm Lower Aluminum 2 2 3 8 16 x 2 HWH Type F 4 Figure 43 Facing Down Facing Up 1 2 ...

Page 34: ...oss bar 8 See Figure 44 Measure 4 from the edge of the tarp on both sides Drill 9 32 horizontal hole through the connecting arm and the cross arm DO NOT drill through the tarp 9 See Figure 45 Before installing eyebolts 7 and springs 5 slide rubber bumper 9 over each end of cross arm and position inside of notch in tarp Position bumpers to rest on tailgate 10 Fasten the arms with eye bolts 7 and 1 ...

Page 35: ...he bed 5 Insert 1 4 20 x 1 hex bolt 7 into each rubber bumper and attach 1 4 20 Nylon hex jam nut 10 6 Slide 2 rubber bumpers 5 onto each side of the cross arm 2 7 Lift one swing arm and insert cross arm 2 into arm casting 4 Insert far enough so opposite swing arm can be lifted and inserted through the opposite arm casting 4 8 See Figure 47 Adjust cross arm 2 on one side to extend 1 2 3 4 beyond a...

Page 36: ...e bed While maintaining that position slide the opposite swing arm on the cross arm 2 until it is parallel with the bed 11 Repeat 9 12 See Figure 48 Cut excess cross arm 2 which extends 1 2 3 4 beyond arm casting 4 13 Insert Plug Ends 12 into each end of cross arm 2 14 Position one set of rubber bumpers 4 to sit on tailgate and one set to hit end plates or tarp housing and tighten bolts OPTIONAL S...

Page 37: ... the loose end of the tarp 1 over the roll up bar winding from the topside Make sure the tarp is centered from side to side 2 Mark the tarp roll up bar for fastener placement using the grommets in the tarp as a guide 3 Secure tarp 1 with 1 4 20 pan head Phillips 2 1 4 20 square nuts 3 and 1 4 split lock washers 4 Index Description Qty 1 Tarp 1 2 1 4 20 x 1 2 Pan Head 6 Index Description Qty 3 1 4 ...

Page 38: ... mounting bolts and nuts are in place and tight and that no parts are worn or damaged Bearings Pull the shafts from side to side and in and out If there is excessive play replace the bearings Apply penetrating oil lightly as needed Springs Examine springs for breakage or distortion Apply a light coat of penetrating oil to tension springs as needed Electrical Connections Check all electrical connec...

Page 39: ... or damaged Chain Check the chain tension that links move smoothly and make sure the master link is on Lubricate the chain regularly with penetrating oil Electrical Connections Check all electrical connections and tighten any that have become loose Safety Labels Clean labels with soap and water Replace if damaged and or difficult to read Replacement Parts and instructions may be obtained from your...

Page 40: ...y Cover and the Claw are trademarks of Aero Industries Inc The Claw Patent Pending Covered by one or more of the following patents in the U S 5 129 698 5 174 625 6 234 562 6 318 790 6 338 521 6 367 862 6 457 622 6 474 719 6 536 836 6 575 518 6 575 519 6 578 897 6 637 800 6 712 419 6 786 735 6 942 274 7 275 780 8 205 927 8 220 859 8 267 461 8 444 206 8 550 532 and others pending in Canada 2 073 714...

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