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Aero AeroForce S2S Installation Instructions Manual

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Serving the Truck & Trailer Industry
Since 1944
AeroForce S2S
Installation Instructions
Attention Dealers: Please give this manual to the customer when product is delivered
Call 800-535-9545 I www.aeroindustries.com
Indianapolis, IN | Omaha, NE | Kent, OH

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  • Page 1 Serving the Truck & Trailer Industry Since 1944 AeroForce S2S Installation Instructions Attention Dealers: Please give this manual to the customer when product is delivered Call 800-535-9545 I www.aeroindustries.com Indianapolis, IN | Omaha, NE | Kent, OH...

  • Page 2: Installation Directory

    Semi-trailer Truck Wiring Semi-trailer Wiring Optional Remote Wiring Alternate Remote Wiring 39-40 How to Operate AeroForce S2S Safety Messages Related to the Operation of AeroForce S2S How to Maintain AeroForce S2S Safety Messages Related to the Maintenance of AeroForce S2S...

  • Page 3: Important Safety Information

    CAUTION: Keep all clothing clear of moving parts. CAUTION: Keep everyone clear of the area. Safety Messages Related to the Installation of AeroForce S2S CAUTION: Use caution lifting heavy components. Use more than one person and/or proper equiment to handle components.

  • Page 4: Tools Required For Installation

    This manual explains how to install and maintain an AeroForce S2S Roll Tarp System Aero Warranty Aero Products come with a one year warranty on all parts. It’s another example of our ongoing commitment to customer satisfaction and quality Customer: If you have any concerns or questions prior to the installation of this product, please call our Customer Service at 1-800-535-9545.
  • Page 5 Step 1a Fabric Front Cap: Mark Top Rail for Bow Placement Figures 5-1 & 5-2. Mark the top rail where flat on side of trailer starts. Also mark 10" from there for heavy duty bows. The dimension of the Radius, Diagonal, or Offset. Flat on side of trailer Flat on side of trailer Flat on side of trailer...
  • Page 6 Step 1b Fabric Front Cap: Install Double Bow Bracket or Heavy Duty Bows Install Heavy Duty Bracket Index Description Figure 6-1. Position heavy duty brackets centered on Fabric Front Cap marks on top rail. Attach with 3/8 x 1 type F HWH bolts. Heavy Duty Bracket Double Bow or Double Bow W/Insert Bows...
  • Page 7 Bow Through Pocket Step 1b (cont.) Fabric Front Cap Figure 7-1. Feed bow through pocket of fabric cap and install on trailer. On adjustable bows remove bolt and pin. Orient the bow so the end with the removable pin is on the passenger side. Install heavy duty bows per Step 3d.
  • Page 8 Step 1c Fabric Front Cap: Install Aluminum Trough Index Description Index Description Fabric Front Cap Bolt Carr 3/8-16x1-1/4 Angle Bracket Trough Nut Hex 3/8-16 Trough Extrusion Rolled Washer Flat 3/8" 3/8 x 1 Type F HWH Aluminum Flat Bar 1/8" x 1" 12 Ft Figure 8-1.
  • Page 9 Step 1c (cont.) Figure 9-1. Position aluminum trough at the R, D, or O plus any trough offset 9.5" specified on order. Figure 9-1. Drill pilot holes for 3/8" x 1" type F and secure to trailer. R, D or O Plus Trough Offset Figure 9-1 Figure 9-2.
  • Page 10 Step 1d Aluminum Front Cap: Install Square Nose Index Description Front Cap Square Aluminum 3/8 x 1 Type F HWH Figure 10-1. Measure and make any cut-outs and place cap on trailer. Attach with 3/8 x 1 Type F HWH Bolts through trough into top rail.
  • Page 11 Step 2a Fabric Rear Cap: Install Double Bow Bracket or Heavy Duty Bows Install Heavy Duty Bracket Index Description Fabric Rear Cap Figure 11-1. Position heavy duty brackets centered on marks on top rail. Attach with 3/8 x 1 type F HWH bolts. Heavy Duty Bracket Double Bow or Double Bow W/Insert Bows...
  • Page 12 Step 2a (cont.) Figure 12-1. Feed bow through pocket Fabric Rear Cap of fabric cap and install on trailer. On Bow Through adjustable bows remove bolt and pin. Pocket Orient the bow so the end with the removable pin is on the passenger side. Install heavy duty bows per Step 3d.
  • Page 13 Step 2b Fabric Rear Cap: Install Aluminum Trough Index Description Index Description Fabric Cap Nut Hex 3/8-16 Angle Bracket Trough Washer Flat 3/8" Trough Extrusion Rolled Aluminum Flat Bar 1/8" x 1" 12 Ft 3/8 x 1 Type F HWH Pin Hair 3/16x3.5"...
  • Page 14 Step 2b (cont.) Figure 14-1. Position the front of the aluminum trough at 30" from the outside of the tailgate. Figure 14-1. Drill pilot holes for 3/8" x 1" type F and secure to trailer. Bracket can be welded to Aluminum Trailer. 9.5"...
  • Page 15 Step 2c Aluminum Rear Cap: Install Mounted to Tailgate Index Description Aluminum Cap Rear Cap Aluminum Tailgate 3/8 x 1 Type F HWH Figure 15-1. Position aluminum rear cap centered on inside of tailgate with the bottom of the trough even with the side walls.
  • Page 16 Step 3a Marking Bow Location Mark top rail according to what caps are on the trailer. IMPORTANT: DO NOT exceed 48” spacing for bow centers. This will void the warranty. IMPORTANT: This tarp system must have arched bows to support the tarp fabric when closed. As such, when not in use, the tarp should be fully opened to prevent moisture from collecting on the tarp surface.
  • Page 17 Mark on top rail Step 3b Installing Aluminum Bows Figure 17-1. Align aluminum pocket with marked bow location and flush with top of rail. Weld down each side of pocket. 3/8 x 1 Type F HWH Figure 17-1 Drill a pilot hole and attach with 3/8 x 1 type F HWH bolts. Figure 17-2.
  • Page 18 Step 3d Installing Heavy Duty Bows Figures 18-1 & 18-2. Align bracket with marked bow location and place on top of rail. Figure 18-2. Drill a pilot hole and attach with 3/8 x 1 type F HWH bolts. Repeat for opposite side. Figure 18-2.
  • Page 19 Step 3e Installing Flex Bows & Double Flex Bows Figure 19-1. Drill 4x bolt clearance holes in bow pocket flanges for 3/8 bolts. Holes should be 1/2" min. from flange edges. Align pocket with marked bow location and flush with top rail. Drill 4 pilot holes and attach with 3/8 x 1 type F HWH bolts.
  • Page 20 Step 4a Assemble and Load Anchor Pipe in Tarp Figures 20-1 & 20-2. Assemble swaged ends of anchor pipe and weld sections together. Weld Swaged End Figure 20-1 Figure 20-2 2) Figure 20-3. Cut the anchor pipe ush with the ends of the pocket on the tarp. 3) Place rubber caps on the ends of anchor pipe.
  • Page 21 Step 4b Assemble and Load 2” Steel Roll Pipe in Tarp Figure 21-1. Drill 3/8” hole through both walls of roll pipe at 3/4” from end. Insert wobble joint, align holes, and secure wobble joint to roll pipe with 3/8” bolt and lock nut. Index Description 2”...
  • Page 22 Step 4c Assemble and Load 3" Aluminum Roll Pipe in Tarp Figure 22-1. Drill 3/8” hole through both walls of roll pipe at 3/4” from end. Insert wobble joint, align holes, and connect wobble joint to roll pipe with 3/8” bolt and lock nut. Index Description 3”...
  • Page 23 5” - 9” 5” - 9” Step 5 Installing Roll Stops and Secure Anchor Pipe Figures 23-1 & 23-2. Locate first roll stop bracket 5"-9" from the first bow and 1" down from top rail. Tarp & end of anchor pipe should be 1" from center of same bow.
  • Page 24 Step 6 Install Latch Plate Check to ensure the roll tube will have a clear path past the tailgate. Latch Shim latch plate if needed. Front Edge Plate Latch plate can be mounted to the top rail or to the sideboards. of Tarp Mounting the latch plate to the top rail with sideboards allows the tarp to cover the gap at the bottom of the sideboard.
  • Page 25 Step 7a Mounting Arm Mounts (Front Standard Roll) Note: Figure 25-1. Center of the pivot needs to be in the center of the trailer. 1) Figure 25-2. Drill four 3/8" holes using the mounting bracket as a template for the hole locations. 2) Figure 25-3.
  • Page 26 Step 7b Mounting Arm Mounts (Front Reverse Roll) Note: Figure 26-1. Center of the pivot needs to be in the center of the trailer. 1) Figure 26-2. Drill eight 3/8" holes using the mounting bracket as a template for the hole locations.
  • Page 27 Step 8a Mounting Arm Mounts (Rear Standard and Reverse Roll) Figure 27-1. Center of the pivot needs to be in the center of the trailer. Figure 27-2. Drill four 3/8" holes using the mounting bracket as a template for the hole locations. Figure 27-3.
  • Page 28 Step 8b Mounting Arm Mounts (ForceLink with Coal Door) Figure 28-1. Assemble the rear arm mounting bracket per the assembly drawing. Index Description HOUSING MOUNTING BRACKET 1/2 - USS FLAT WASHER 1/2-13 NYLON LOCK NUT PLATE, REAR COAL DOOR 1/2-13 UNC - 1.5 - BOLT HHCS Figure 28-1 Note: Mounting Brackets are supplied with standard pivot mozunting hole locations at 3/8”...
  • Page 29 Step 9a Mounting Front Arm Standard Roll Figure 29-1. Using the supplied hardware, mount the front arm assembly to the mounting bracket located on the front of the trailer. Index Description FRONT ARM ASSY 3/4-10 UNC - 1.5 - BOLT HHCS 3/4 - SPLIT LOCK WASHER 3/4 - USS FLAT WASHER Note: Mounting Brackets are supplied with standard...
  • Page 30 Step 10a Mounting Rear Arm Standard Roll Figure 30-1. Using the supplied hardware, mount the rear arm assembly to the mounting bracket located on the rear of the trailer. Index Description REAR ARM ASSY W/ CHAIN 3/4-10 UNC - 1.5 - BOLT HHCS 3/4 - SPLIT LOCK WASHER 3/4 - USS FLAT WASHER Note: Mounting Brackets are supplied with standard...
  • Page 31 Step 10c Mounting Rear Arm (ForceLink with Coal Door) Figure 31-1. Drill two 25/32" holes for 3/4" bolts in the top of the bracket so that the pivot pin on the ForceLink is in the center of the trailer. The distance between the holes needs to be 6-3/8".
  • Page 32 Step 11a Roll Pipe Front Hookup Standard Roll 1) Figure 32-1. Attach motor to front arm with 3/8” bolts and lock nuts. Make sure to align marker stickers on motor and arm before securing. 2) Figure 32-2 & 32-3. Insert roll pipe into motor and attach with supplied hardware.
  • Page 33 Step 11b Roll Pipe Front Hookup Reverse Roll 1) Figure 33-1. Attach motor to front arm with 3/8” bolts and lock nuts. Make sure to align marker stickers on motor and arm before securing. 2) Figure 33-2 & 33-3. Insert roll pipe into gearbox and attach with supplied hardware.
  • Page 34 Step 12a Roll Pipe Rear Hookup - 2” Steel Figures 34-1 & 34-2. Cut roll pipe down so the chain on the 90 degree casting is aligned with the arm. Figure 34-3. Slide roll pipe over the rear arm pipe bushing. Figure 34-3.
  • Page 35 Step 12b Roll Pipe Rear Hookup - 3” Aluminum Figures 35-1 & 35-2. Cut down the roll pipe so that when the rear arm adapter is installed the chain is aligned with the rear arm. Figure 35-3. Slide the roll pipe over the spline adapter on the rear arm assembly.
  • Page 36 Step 12c Rear Tensioner Insert Rear Tensioner assembly fully into roll tube, should be an interference t. Pre-drill two holes, 90 degrees opposed, and insert self tapping screws. Holes/screws are 1" from tensioner/roll pipe interface. Attach eyebolt inline with tensioner rope/s-hook if possible to limit wear. Eyebolt should be approximately 12"...
  • Page 37 Step 13a Semi-trailer Truck Wiring IMPORTANT: Locate Operation/Maintenance Sheet and keep near switch. IMPORTANT: Switch is not rated for outdoor use. Find a convenient place on the driver's side under the dashboard to mount the rocker switch with 1/4-20 x 1" hex bolts Mount reversing contactor outside near back of cab with 1/4-20 x 2"...
  • Page 38 Step 13b Semi-trailer Wiring Mount receptacle in convenient location. Terminal 1 Terminal 2 Run wire from receptacle to motor. Secure all wire with clamps. Terminal 1 Terminal 2 NOTICE: Install boot caps and apply NOTICE: Apply conductive grease to all dielectric grease to all ring terminal 2-prong plug connections.
  • Page 39 Step 13d Alternate Remote Wiring IMPORTANT: Locate Operation/Maintenance Sheet and keep in a convenient location. Semi-trailer Truck Wiring Connect breaker to battery and secure with zip ties. Run wire from battery to receptacle. Secure all wire with clamps. Semi-trailer Wiring Mount receptacle in convenient location on trailer.
  • Page 40 Step 13d (cont.) Mount reversing contactor under the nose of the trail with 1/4-20 x 2" hex bolts. WARNING: DO NOT place remote receiver in the path of the swing arm or injury could occur. Mount it on the face of the trailer on the same side as the anchor pipe.

  • Page 41: Remote Operation

    WARNING: Indicates a hazardous situation which, if not avoided could result in death or serious injury. CAUTION: Indicates a hazardous situation which, if not avoided could result in minor or moderate injury. Safety Messages Related to the Operation of AeroForce S2S Maintenance recommendations, safety messages, and repair instructions can be found at www.s2soperation.com...
  • Page 42 Minimal maintenance is required for the AeroForce S2S. Individual usage and operating conditions will determine when to check the AeroForce S2S. Aero Industries recommends a weekly inspection of the following items: Inspect Tarp for wear and tears. Inspect arms for damage (cracked, dented or bent).
  • Page 43 Call 1-800-535-9545 www.aeroindustries.com INDIANAPOLIS, IN OMAHA, NE KENT, OH Indianapolis, IN 46241 Omaha, NE 68137 Kent, OH 44240 800-535-9545 800-535-9545 888-237-2262 FAX: 317-244-1311 FAX: 402-895-6129 FAX: 330-626-3277 © 2017 Aero Industries, Inc. PATENT PENDING. Aero Industries, Inc. 0930-106301 4/2/2024 Rev. K...

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