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Aero Easy Cover Installation Instructions Manual

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Serving the Truck & Trailer Industry
Since 1944
Easy Cover
®
Installation Instructions
Attention Dealers: Please give this owners manual to the customer when the product is delivered.
Call 800-535-9545 | www.aeroindustries.com
Indianapolis, IN | Omaha, NE | Streetsboro OH

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Summary of Contents for Aero Easy Cover

  • Page 1 Serving the Truck & Trailer Industry Since 1944 Easy Cover ® Installation Instructions Attention Dealers: Please give this owners manual to the customer when the product is delivered. Call 800-535-9545 | www.aeroindustries.com Indianapolis, IN | Omaha, NE | Streetsboro OH...
  • Page 2 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 Installing Tarp Housing with Trailer Mounting Brackets...
  • Page 3 Easy Cover ®                                 * Refer to Operations * Refer to Maintenance sheet or website.
  • Page 4 Easy Cover ® This manual explains how to install and maintain the Easy Cover® tarping system.   Tools Required for Installation Marker or Felt Pen Tape Measure Black Electrical Tape Hammer 1 1/8" hole saw Drill Bits: .257" (F drill), 9/32", .316" (O drill), 13/32", 17/32"...
  • Page 5 Easy Cover ® Installation Instructions Step 1a Installing End Plates and Wind Defl ector      Index Description Index Description End Plates (DS & PS) 3/8-16 x 1 Hex Bolt Wind Defl ector 3/8-16 Nylon Hex Nut 3/8-16 x 1 Carriage Bolts 1) See Figure 1.
  • Page 6 Easy Cover ® Installation Instructions Step 1b Installing Tarp Housing inside Cab Shield    Index Description Index Description Tarp Housing 1/2-13 x 2 Hex Bolt GR5 Mounting Bracket 1/2 Flat Washer Rubber Bushing 1/2 Nylon Hex Nut ...
  • Page 7 Easy Cover ® Installation Instructions 3) See Figure 5. Attach mounting bracket (2) to cab shield using 1/2-13 x 2 hex bolt (4), 1/2 fl at 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 fl...
  • Page 8 Easy Cover ® Installation Instructions Step 1c Installing Tarp Housing with Trailer Mounting Bracket    Index Description Index Description Tarp Housing 1/2-13 x 2 Hex Bolt GR5 Mounting Bracket Trailer 1/2 Flat Washer Rubber Bushing 1/2 Nylon Hex Nut 1) See Figure 7.
  • Page 9 Easy Cover ® Installation Instructions Step 2a Installing Manual Fixed Roll Up Bar Index Description Fixed Manual Roll Up Bar 1) See Figure 8. Unbolt and remove the shafts from both ends of fi xed manual roll up bar (1).
  • Page 10 Easy Cover ® Installation Instructions Step 2b Installing Electric Motor and Fixed Roll Up Bar Index Description RA/SWB Motor Fixed Electric Roll Up Bar Motor Cover 5/16-18 x 7/8 FHCS #10 x 1 Self-drilling Pan Head Figure 10 1) See Figure 9. Fasten motor RA/SWB (1) to the end plate or tarp housing with three 5/16-18 x 7/8 FHCS (3).
  • Page 11 Easy Cover ® Installation Instructions Step 2c Installing Manual Adjustable Roll Up Bar  Index Description Adjustable Manual Roll Up Bar 1/4-20 x 2 1/4 Hex Bolt 1/4-20 Nylon Hex Nut 1) Remove hardware package and tape from center of adjustable manual roll up bar, one end is loose and can slide off.
  • Page 12 Easy Cover ® Installation Instructions Step 2d Installing Electric Motor and Adjustable Roll Up Bar  Index Description Motor Winch "B" Adjustable Electric Roll Up Bar 5/16-18 x 5/8 FHCS 1/4-20 x 2 1/4 Hex Bolt 1/4-20 Nylon Hex Nut 1) See Figure 12.
  • Page 13 Easy Cover ® Installation Instructions Step 3a Installing the Sprocket Index Description Sprocket 1) See Figure 13. Slide the sprocket (1) over the outside of the shaft of the driver's side roll up bar. Position sprocket so that it aligns with the crank assembly sprocket.
  • Page 14 Easy Cover ® Installation Instructions Step 3c Installing the Chain and Chain Cover(s) Index Description Index Description Chain Guard Mounting Brackets Master Link #14 x 1/2 Self Drilling Screw Crank Cover Aluminum #14 x 1 Self Drilling Screw Chain Cover Lower Aluminum Crank Handle 1) See Figure 15.
  • Page 15 Easy Cover ® Installation Instructions Step 4a Installing the Standard Electrical Controls with Rocker Switch   Index Description Index Description Reverse DC Contactor 10-32 Hex Nut DC Contactor Cover 1/4 x 3/4 Pan Head Phillips Switch Rocker Assy for DC Contactor...
  • Page 16 Easy Cover ® Installation Instructions 6) Secure the #6 wire (5) along the vehicle frame using clamp metal looms (20) and 1/4 x 3/4 pan head Phillips (13) being sure to avoid any exhaust, moving parts, or sharp edges that could damage the wire's protective coating.
  • Page 17 Easy Cover ® Installation Instructions Step 4b Install and Wire Motor for Semi-trailer Truck  1) Install receptacle at the front of the trailer. Attach the #6 wire to the butt connectors on the receptacle. For End Dumps For Bottom Dumps 2a) See Figure 20.
  • Page 18 Easy Cover ® Installation Instructions Step 4c Install Interior Cab Rocker Switch for Semi-trailer Truck  Locate Operation/Maintenance Sheet and keep near switch.  1) Find a convenient place on the driver's side under the dashboard to mount the rocker switch with 1/4-20 x 1"...
  • Page 19 Easy Cover ® Installation Instructions Step 4d Wiring Diagram for Lead & Pup with Contactors Mounted on Tractor Index Description Index Description Reverse DC Contactor Wire End #14 x 3/8 Ring Term. DC Contactor Cover Plug Quick Disconnect Assembly Switch Rocker Assy for DC Contactor...
  • Page 20 Easy Cover ® Installation Instructions Figure 23...
  • Page 21 Easy Cover ® Installation Instructions Step 4e Wiring Diagram for Lead & Pup with Contactors Mounted on Trailer Index Description Index Description Reverse DC Contactor Plug Quick Disconnect Assembly DC Contactor Cover Plug Quick Disconnect Assembly Switch Rocker Assy for DC Contactor...
  • Page 22 Easy Cover ® Installation Instructions Step 4f Installing the Optional Electrical Controls with Rotary Switch   Index Description Index Description Rotary Switch Wire End #6 x 1/4 Ring Terminal Circuit Breaker 40 Amp Wire End #6 x 3/8 Ring Terminal...
  • Page 23 Easy Cover ® Installation Instructions 6) See Figure 26. Measure the wiring distance from the gearmotor to the pivot box, then from the pivot point through the truck body to the switch in the cab. 7) Secure the #6 wire (6) along the vehicle frame using clamp metal looms (5) and 1/4 x 3/4 pan head Phillips (11) being sure to avoid any exhaust, moving parts, or sharp edges that could damage the wire's protective coating.
  • Page 24 Easy Cover ® Installation Instructions Step 5a Installing Undermount or Flange Mounted Spring Assembly    Index Description Index Description Flange Mounted Spring (driver side) 3/8 Flat Washer Flange Mounted Spring (passenger side) 3/8-16 Nylon Hex Nut 3/8-16 x 1 1/4 Hex Bolt ...
  • Page 25 Easy Cover ® Installation Instructions Step 5b Installing Underbody Spring Assembly   Index Description Index Description Flange Mounted Spring (driver side) 3/8 Flat Washer Flange Mounted Spring (passenger side) 3/8-16 Nylon Hex Nut 3/8-16 x 1 1/4 Hex Bolt Plate Aluminum Cover (optional) ...
  • Page 26 Easy Cover ® Installation Instructions Step 5c Installing PowerPack Spring Assembly  STEP 1) Locating the position to install the spring assembly          Figure 33 STEP 2) Marking the pilot holes Use mounting holes to mark the hole location.
  • Page 27 Easy Cover ® Installation Instructions STEP 4) Mount the spring assembly   Dump Body Flat Washer Flat Washer Optional Lock Nut Hex Bolt Rear Mounting Plate Flat Washer Lock Nut STEP 5) Attach the Optional Rear Mounting Plate ...
  • Page 28 Easy Cover ® Installation Instructions Step 5d Installing PowerPack Spring Assembly  STEP 1) Locating the position to install the spring assembly          Figure 34 STEP 2) Marking the pilot holes Use pilot holes to mark the hole location.
  • Page 29 Easy Cover ® Installation Instructions  Index Description Mounting Brackets 1/2-13 x 2" Hex Bolt 1/2 Flat Washer 1/2-13 Nylon Hex Nut STEP 4) Installing Drive Side Mounting Bracket    On the driver side rotate the mounting bracket to the position shown and attach using the 1/2-13 X 2"...
  • Page 30 Easy Cover ® Installation Instructions          STEP 6) Assemble and install the Drive Side PowerPack spring.  On the mounting bracket shaft, place in this order: Description Front 1 1/4" Flat Washer...
  • Page 31 Easy Cover ® Installation Instructions Step 6a Installing the End Fitting and Steel Lower Swing Arm  Index Description End Fitting 1/4" Spring Pins Swing Arm Lower Steel 5/16-18 x 2 1/4 Hex Bolt 5/16-18 Nylon Hex Jam Nut 1) See Figure 39. Place swing arm lower (3) onto...
  • Page 32 Easy Cover ® Installation Instructions Step 6b Installing the End Fitting and Aluminum Lower Swing Arm Index Description End Fitting 1/4" Spring Pins Swing Arm Lower Aluminum 5/16-18 x 2 HWH Type F 1) See Figure 41. Place a end fi tting (1) on the driver's side tension spring assembly shaft so it is facing the rear.
  • Page 33 Easy Cover ® Installation Instructions Step 6c Installing Aluminum Lower Swing Arm on PowerPack Spring Assembly  Index Description Swing Arm Lower Aluminum 3/8-16 x 2 HWH Type F      1) See Figure 43. Slide swing arm lower aluminum (1) onto powerpack spring assembly.
  • Page 34 Easy Cover ® Installation Instructions Step 7a Installing Steel Cross Arm and Connecting Arms  Index Description Index Description Tarp 1/4-20 x 2 1/2 Hex Bolt Cross Arm 1/4 Eye Bolt Connecting Arm D.S. 1/4 Keps Nut Connecting Arm P.S.
  • Page 35 Easy Cover ® Installation Instructions Step 7b Installing Upper Swing Arms and Cross Arm  Index Description Index Description Tarp 3/8-16 x 2 Hex Bolt Cross Arm 3/8-16 x 3 Hex Bolt Upper Swing Arm 1/4-20 Nylon Hex Jam Nut...
  • Page 36 Easy Cover ® Installation Instructions 9) With the cross arm (2) resting on the tail gate drill a 1/4" hole through the tube using the hole in the arm casting (4) as a guide. Secure with 3/8-16 x 3" hex bolt (9) and 3/8-16 nylon hex nut (11) 10) See Figure 48.
  • Page 37 Easy Cover ® Installation Instructions Step 8a Installing the Tarp to the Roll Up Bar, Roll Under (Standard)  Index Description Index Description Tarp 1/4 Square Nut 1/4-20 x 1/2 Pan Head 1/4 Split Lock Washer 1) See Figure 49. Pull the loose end of the tarp (1) under the roll up bar, winding from the underside.

  • Page 38: Operation Instructions

    Electrical Connections: Check all electrical connections and tighten any loose connections. Safety Labels: Clean labels with soap and water. Replace if damaged and/or diffi cult to read. Replacement Parts and instructions may be obtained from your Aero dealer or by contacting Aero Industries.
  • Page 39 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 diffi cult to read. Replacement Parts and instructions may be obtained from your Aero dealer or by contacting Aero Industries.
  • Page 40 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;...