Aero Easy Cover User manual

Call 800-535-9545 | www.aeroindustries.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

2
Easy Cover®
Installation Directory
Item Step Page
Safety Information 3
Warranty Information and Tools Required 4
End Plates, Wind Deflectors, and Tarp Housing
Installing End Plates and Wind Deflector 1a 5
Installing Tarp Housing Inside Cab Shield 1b 6-7
Installing Tarp Housing with Trailer Mounting Brackets 1c 8
Roll-up Bar
Installing Manual Fixed Roll-up Bar 2a 9
Installing Electric Motor and Fixed Roll-up Bar 2b 10
Installing Manual Adjustable Roll-up Bar 2c 11
Installing Electric Motor and Adjustable Roll-up Bar 2d 12
Sprocket, Crank, Chain, and Chain Covers
Installing Sprocket 3a 13
Installing Manual Crank Assembly 3b 13
Installing Chain and Chain Cover(s) 3c 14
Electrical
Installing Standard Electrical Controls with Rocker Arm Switch 4a 15-16
Install and Wire Motor for Semi-trailer Truck 4b 17
Install Interior Cab Rocker Switch for Semi-trailer Truck 4c 18
Wiring Diagram 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 PowerPack Spring Assembly 5d 28-30
End Fittings & Lower Swing Arms
Installing End Fitting and Steel Lower Swing Arm 6a 31
Installing End Fitting and Aluminum Lower Swing Arm 6b 32
Installing Aluminum Lower Swing Arm on PowerPack Spring Assembly 6c 33
Cross Arm and Connecting Arms
Installing Steel Cross Arm and Connecting Arms 7a 34
Installing Upper Swing Arms and Cross Arm 7b 35-36
Attach Tarp to Roll-up Bar
Installing Tarp to Roll-up Bar, Roll Under (Standard) 8a 37
Installing Tarp to Roll-up Bar, Roll Over (Optional) 8b 37
Easy Cover®Electric Model
Operation Instructions 38
Maintenance Recommendations 38
Easy Cover®Manual Model 39
Operation Instructions 39
Maintenance Recommendations 39

3
Easy Cover®
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
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

&1016UVCPFKPVJGRCVJ
QHQTQPVJGCTOUQTKPLWT[
EQWNFQEEWT
6CTR/756DGHWNN[EQXGTGF
QTWPEQXGTGFDGHQTGFTKXKPI
&1016QRGTCVGYJGPFCOCIGF
%JGEMHQT
QXGTJGCF
RQYGTNKPGU
5RTKPIUCPFCTOUCTGWPFGTGZVTGOGVGPUKQP$TQMGPQT
FCOCIGFEQORQPGPVUEQWNFECWUGFGCVJQTUGTKQWUKPLWT[
0'8'4UVCPFPGCT
FCOCIGF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 inspect
tarp and arms and
replace if damaged.
YYYGCU[EQXGTOCKPVGPCPEGEQO
YYYGCU[EQXGTQRGTCVKQPEQO
Label part# 0920-039001

4
Easy Cover®
Marker or Felt Pen
Tape Measure
Black Electrical Tape
Awl
Hammer
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.

5
Easy Cover®
Installation Instructions
Step 1a
Installing End Plates and Wind Deflector





1) See Figure 1. Install 3/8-16 x 1 carriage bolts (3) and 3/8-16 Nylon hex nuts (4) in the driver's side and
passenger's mounting plates (1). Do not tighten.
2) Slide end plates (1) into wind defector's extrusion. Do not tighten.
3) Carefully place assembly onto the cab shield or top rail and position at the
farthest point forward. This will keep the air from coming in under the wind
deflector (2) to a minimum.
3) See Figure 2. Move the end plates inward until they are 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's side end plate (1).
7) Tighten nuts on carriage bolts holding the wind deflector (2).
Index Description Qty
1 End Plates (DS & PS) 2
2 Wind Deflector 1
3 3/8-16 x 1 Carriage Bolts 4
Index Description Qty
4 3/8-16 x 1 Hex Bolt 6
5 3/8-16 Nylon Hex Nut 10
Figure 1
1
3
5
2
Driver's Side Shown
Aligning Notch
Figure 2
Square Holes referred to in Step 4





6
Easy Cover®
Installation Instructions
Step 1b
Installing Tarp Housing inside Cab Shield









1) See Figure 3. Hold mounting bracket (2) up to the cab shield. With angles as far forward as possible,
and level with top edge of cab shield, trace through holes with permanent marker. Repeat on other side of
cab shield.
2) See Figure 4. Measure width of housing - dimension "A". Measure width inside of cab shield - dimension
"B". Subtract B from A and divide by two 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
Index Description Qty
4 1/2-13 x 2 Hex Bolt GR5 8
5 1/2 Flat Washer 8
6 1/2 Nylon Hex Nut 8
Lip
Use angle as
template Inside
radius Drop
clearance
Distance same
on both sides
D.S. View
Figure 3
2Mark in center
of slot
Figure 4
"C" 3/4"
"B"
"A"
1

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 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

8
Easy Cover®
Installation Instructions
Step 1c
Installing Tarp Housing with Trailer Mounting Bracket



1) See Figure 7. Turn tarp housing (1) upside down and position mounting bracket trailer (2) 12" in from each
end and flush with the back of the tarp housing (1) (not the end plates). Keeping brackets straight and
parallel with end plates, mark holes through brackets
2) Drill marked holes using 17/32" drill bit.
3) See Figure 6. Attach 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 Description Qty
1 Tarp Housing 1
2 Mounting Bracket Trailer 2
3 Rubber Bushing 4
Index Description Qty
4 1/2-13 x 2 Hex Bolt GR5 8
5 1/2 Flat Washer 8
6 1/2 Nylon Hex Nut 8
4
5
6
4
5
6
2
3
Figure 6
3/8" - 1/2"
1
Figure 7

9
Easy Cover®
Installation Instructions
Step 2a
Installing Manual Fixed Roll Up Bar
1) See Figure 8. Unbolt and remove the shafts from both ends of fixed manual roll up bar (1).
2) On the driver's side align the fixed manual roll up bar (1) with the bearing, insert the shaft with the keyway
through 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 Bolt 1/4-20 x 2 1/4 Hex Bolt
1/4-20 Nylon Hex Nut 1/4-20 Nylon Hex Nut
Shaft with Keyway

10
Easy Cover®
Installation Instructions
Step 2b
Installing Electric Motor and Fixed Roll Up Bar
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).
2) With screws provide with the motor attach the cover to the motor. (Cover will need to be removed for wiring.)
3)See Figure 10. When installing on a tarp housing use the motor cover (3) with
two #10 x 1 self-drilling pan head screws (5).
4) See Figure 9. Unbolt and remove the shaft from end of fixed electric roll up bar (1).
5) One end 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 1/4-20 nylon hex nut remove in step 4.
Index Description Qty
1Motor RA/SWB 1
2 Fixed Electric Roll Up Bar 1
3 Motor Cover 2
4 5/16-18 x 7/8 FHCS 3
5 #10 x 1 Self-drilling Pan Head 2
Figure 9
1
2
4
Motor Cover
Cover Screws 1/4-20 x 2 1/4 Hex Bolt 1/4-20 x 2 1/4 Hex Bolt
1/4-20 Nylon Hex Nut 1/4-20 Nylon Hex Nut
Figure 10
35

11
Easy Cover®
Installation Instructions
Step 2c
Installing Manual Adjustable Roll Up Bar

1) Remove hardware package and tape from center of adjustable manual roll up bar, one end is loose and can
slide off. Place hardware package to the side.
2) One end of adjustable manual roll up bar has a shaft with a hole, insert this end through the bearing on the
driver's end of tarp housing.
3) Make 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 Qty
1 Adjustable Manual Roll Up Bar 1
2 1/4-20 x 2 1/4 Hex Bolt 2
3 1/4-20 Nylon Hex Nut 2
.25
.75 5.00
Figure 11
.257" diameter (F Drill)
Thru both tubes
2 places 2 3
Flush against bearing
1

12
Easy Cover®
Installation Instructions
Step 2d
Installing Electric Motor and Adjustable Roll Up Bar

1) See Figure 12. Fasten Motor Winch "B" (1) to driver's side end plate with 5/16-18 x 5/8 FHCS (3).
2) With screws provide with the motor attach the cover to the motor. (Cover will need to be removed for wiring.)
3) Remove hardware package and tape from center of adjustable electric roll up bar (2), one end is loose and
can slide off. Place hardware package to the side.
4) One end does not have a shaft. Remove the nut and bolt from that end. Insert end onto shaft of motor
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 with two 1/4 x 2 1/4 Hex Bolts from hardware pack.
Index Description Qty
1 Motor Winch "B" 1
2 Adjustable Electric Roll Up Bar 1
3 5/16-18 x 5/8 FHCS 3
4 1/4-20 x 2 1/4 Hex Bolt 2
5 1/4-20 Nylon Hex Nut 2
Figure 12
.75 5.00 .25
1
2
3
4 5
Motor Cover
Cover Screws
.257" diameter (F Drill)
Thru both tubes
2 places
Hex nut and bolt
secures roll up
bar to motor shaft

13
Easy Cover®
Installation Instructions
Step 3a
Installing the 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.
2) Lightly tap the key (2) into the shaft keyway.
3) Tighten the Allen set screw on the sprocket until it
begins to feel tight. Make sure the screw engages the
key (2). Do not over tighten.
Step 3b
Installing Manual Crank Assembly


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 the box with bolts, washers,
and nuts. Make sure to bolt the assembly in the highest
upward position.
Index Description Qty
1 Crank Assembly 1
2 3/8 x 1 Self Tapping Hex Bolt 1
Index Description Qty
1 Sprocket 1
2 Key 1
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Figure 13
Figure 14
2
1
1
2

14
Easy Cover®
Installation Instructions
Step 3c
Installing the Chain and Chain Cover(s)
1) See Figure 15. Wrap chain (1) around both sprockets
and remove the excess links.
2) Wrap the shortened chain the sprockets and fasten the
two ends with the master link (2).





Index Description Qty
1 Chain 1
2 Master Link 1
3 Crank Cover Aluminum 1
4 Chain Cover Lower Aluminum 1
Index Description Qty
5 Guard Mounting 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
aluminum (4). Adjust the chain cover aluminum (3) so that it clears the chain and sprocket evenly on both
sides and clears the top by 1".


#NWOKPWO%QXGT
Figure 16
3
4
5
6
7
8
Figure 17
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#UUGODN[

15
Easy Cover®
Installation Instructions
Step 4a
Installing the Standard Electrical Controls with Rocker Switch


Index Description Qty
1 Reverse DC Contactor 1
2 DC Contactor Cover 1
3 Switch Rocker Assy for DC Contactor 1
4 Circuit Breaker 40 Amp 1
*5 Wire #6 Duplex Varies
*6 Wire #14ga 3 Conductor Type SJ 20'
7 Wire End #6 x 1/4 Ring Term. 2
8 Wire End #6 x 3/8 Ring Term. 5
9 Wire End #6 x #10 Screw Ring Terminal 2
10 Wire End #14 x 1/4 Push on 6
11 Wire End #14 x 3/8 Ring Term. 1
Index Description Qty
12 10-32 Hex Nut 2
13 1/4 x 3/4 Pan Head Phillips 12
14 1/4-20 x 1 Hex Head Bolt 2
15 1/4-20 x 2 Hex Head Bolt 2
16 1/4 Flat Washer 8
17 1/4-20 Nylon Hex Jam Nut 4
18 5/16-24 Hex Nut 4
19 5/16 Lock Washer 4
20 Clamp Metal Loom Plastic Coated 12
21 Wiring Diagram Reverse Contactor 1



$CVV
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
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
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

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
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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 switch (3) using (2) 1/4-20 x 1 Hex bolts (14), (4) 1/4 flat washers (16), and
(2)1/4Nylonhex nuts (17).
4) Find a secure location at or near the back of the cab to mount the reversing DC contactor (1). Mount
the reversing DC contactor (1) using (2)1/4-20 x 2 hex bolts (15), (4)1/4flatwashers(16), and
(2)1/4-20Nylonhex nuts (17). Do not tighten at this time.
5) Measure the wiring distance from the
gearmotor to the pivot box, then from
the pivot point through the truck body
to the DC contactor in the cab.





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. The wire should have a loop at the hinge point where the bed pivots on the frame. A good
rule of thumb is to match the loop of factory installed wires and lines or hoses. This will allow sufficient
flex during bed cycling operation. 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 terminal. Secure circuit breaker in place
with a zip tie if possible to prevent movement.
10) Place the DC contactor cover (2) on the reversing DC contactor (1) and tighten the 1/4-20 bolts and nuts.

Figure 19
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&%%QPVCEVQT

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
2a) See Figure 20. Run #6 wire from receptacle to rear of
trailer, onto dump bed, back 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
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Figure 21
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3) Attach #6 wire to motor with
1/4 ring terminals.
#6 Black Wire
Terminal 1
#6 Red Wire
Terminal 2
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Schematic
#6 Black Wire
Terminal 1
#6 Red Wire
Terminal 2

18
Easy Cover®
Installation Instructions
Step 4c
Install Interior Cab Rocker Switch for Semi-trailer Truck

1) 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
Locate Operation/Maintenance Sheet and keep near switch.
2TQPI
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2) Mount reversing contactor
outside near back of cab
with 1/4-20 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 reverse the wires
on the motor and retest.
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Cover Uncover
#6 Red Wire
#6 Black Wire
#6 Black Wire
#6 Red Wire


19
Easy Cover®
Installation Instructions
Index Description Qty
1 Reverse DC Contactor 2
2 DC Contactor Cover 2
3 Switch Rocker Assy for DC Contactor 2
4 Circuit Breaker 40 Amp 1
5 Wire #6 Duplex Varies
6 Wire #14ga 3 Conductor Type SJ 20'
7 Wire End #6 x 1/4 Ring Terminal 4
8 Wire End #6 x 3/8 Ring Terminal 10
9 Wire End #6 x #10 Ring Terminal 2
10 Wire End #14 x 1/4 Push on 10
Index Description Qty
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
55
5
10
7
8
12
8
8
8
8
8
8
10
10
10
10
Positive
Negative
Battery
12 VDC
Battery +
Battery -
Motor
Forward Motor
Reverse
T1
T2
Battery +
Battery -
Motor
Forward
Motor
Reverse
T1
T2
Tractor Pup Lead
Step 4d
Wiring Diagram for Lead & Pup with Contactors Mounted on
Tractor

20
Easy Cover®
Installation Instructions
Figure 23
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