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

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

Easy Cover®

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EQWNFQEEWT

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QTWPEQXGTGFDGHQTGFTKXKPI

&1016QRGTCVGYJGPFCOCIGF

%JGEMHQT

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RQYGTNKPGU

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FCOCIGFEQORQPGPVUEQWNFECWUGFGCVJQTUGTKQWUKPLWT[

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/#+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.

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Label part# 0920-039001

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.

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

Driver's Side Shown

Aligning Notch

Figure 2

Square Holes referred to in Step 4









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"

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

3/8" - 1/2"

2 5 6

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

Figure 6

3/8" - 1/2"

Figure 7

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

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

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

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