Aero PowerLock 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

FOR GRAIN TRAILERS

PowerLock™

Installation Instructions

PowerLock™

FOR GRAIN TRAILERS

Installation Directory

Item Step Page

Safety Information 3

Warranty Information and Tools Required 4

Front Caps

Fabric Front Cap: Mark Top Rail for Bow Placement 1a 5

Fabric Front Cap: Install Double Bow Bracket or Heavy Duty Bows 1b 6-7

Aluminum Front Cap: Install Square Nose 1c 8

Aluminum Front Cap: Instal Shaped to Nose (level front) 1d 8

Rear Caps

Fabric Rear Cap: Install Double Bow Bracket or Heavy Duty Bows 2a 9-10

Aluminum Rear Cap: Install Mounted to Tailgate 2b 11

Aluminum Rear Cap: Install with Fabric Tail 2c 11

Bows

Marking Bow Location 3a 12

Installing Aluminum Bows 3b 13

Installing Adjustable Steel Bows 3c 13

Installing Heavy Duty Bows 3d 14

Installing Flex Bows 3e 15

Assembly Anchor Pipe and Roll Pipe 4a 16

Position Tarp on Trailer 4b 16

Installing Roll Stops and Secure Anchor Pipe 5 17

Install Latch Plate 6 18

Install PowerLock™ Pivot Box (Front and Rear) 7 19

Install PowerLock™ Spring Assembly (Front and Rear) 8 20

Install PowerLock™ Swing Arm Assembly (Front and Rear) 9 21

Install Roll Pipe 10 22

Install Cut Swing Arm 11 23

Place Labels 12 24

PowerLock™ Semi-trailer Truck Wiring 13a 25

PowerLock™ Semi-trailer Wiring 13b 26

PowerLock™ Optional Remote Wiring 13c 26

PowerLock™ Alternate Remote Wiring 13d 27

How to operate PowerLock™ 28

Safety Messages related to the Operaton of PowerLock™ 28

How to maintain PowerLock™ 29

Safety Messages related to the Maintenance of PowerLock™ 29

PowerLock™

FOR GRAIN TRAILERS

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

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

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

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



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





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Important Safety Information







Label part# 0920-103001

6CTR/756DG

HWNN[EQXGTGFQT

WPEQXGTGFDGHQTG

FTKXKPI

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YJGPFCOCIGF

/#+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.

YYY RQYGTNQEMOCKPVGPCPEG EQO

12'4#6+10+05647%6+105

* Refer to Operations sheet or website.

* Only drive with tarp in fully covered or uncovered

position.

* Routinely inspect tarp and arms and replace if damaged.

YYY RQYGTNQEMQRGTCVKQP EQO

&1016UVCPFKPVJGRCVJ

QHVJGHTQPVTGCTUYKPI

CTOUQTKPLWT[EQWNFQEEWT

5RTKPIUCPFCTOUCTGWPFGTGZVTGOGVGPUKQP

&1016UVCPFKPVJGRCVJQHVJGUYKPICTOU

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PowerLock™

FOR GRAIN TRAILERS

Marker or Felt Pen

Tape Measure

Protractor

Black Electrical Tape

Awl

Hammer

Saw

Hack Saw

1 1/8" hole saw

Drill Bits: 9/32", 11/32"

Sockets: 5/16", 7/16", 9/16", 3/4"

Open End or Box Wrenches: 5/16", 7/16", 9/16", 3/4"

Torx T40

Hex Key: 5/16"

Phillips: #3

Electric or Air Drill

Welder

Tools Required for Installation











This manual explains how to install and maintain a PowerLock™ Roll Tarp

system.

PowerLock™

FOR GRAIN TRAILERS

Installation Instructions

Step 1a

Fabric Front Cap: Mark Top Rail for Bow Placement

1) Figure 1 & 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.



Double Bow Bracket Heavy Duty Bows

Figure 2

Figure 1

Radius Corner

Flat on side of trailer

Front

D.S.

Diagonal Corner

Flat on side of trailer

D.S.

Front

Offset Corner

Flat on side of trailer

D.S.

Front

R, D or O

10"

Flat on side of trailer

D.S.

Front

R, D or O10"

Flat on side of trailer

D.S.

Front

PowerLock™

FOR GRAIN TRAILERS

Installation Instructions

Step 1b

Fabric Front Cap: Install Double Bow Bracket or Heavy Duty Bows

1) Figure 3. Clamp ﬁrst pocket of double bow bracket centered on mark on top rail.

2) Figure 4. Position bracket as shown to reduce tarp wear.



3a) Figure 3. Attach with 3/8 x 1 type F HWH bolts.

3b) Figure 5. Attach with 3/8 x 2-1/2 carriage bolts.

Index Description Qty

1 Fabric Front Cap 1

2 Double Bow or Heavy Duty Bracket 2

3 Bows 2

Index Description Qty

4 3/8 x 1 Type F HWH 8

5 5/16 x 1-1/2 Type F Torx 15

6 Aluminum Flat Bar 1/8" x 1" 12 ft

10"

R, D or O

10"

R, D or O

Figure 3

Double Bow Bracket Heavy Duty Bows

Figure 4

Hardware to Mount to Sideboards

Index Description Qty

7 5/16 X 2-1/2 CARRIAGE BOLT 8

8 5/16 FLAT WASHER 8

9 5/16 LOCK WASHER 8

10 5/16 HEX NUT 8

Install Double Bow Bracket to Sideboards

Figure 5

PowerLock™

FOR GRAIN TRAILERS

Installation Instructions

Figure 8

5/16 x 1-1/2 Type F Torx

Aluminum Flat Bar

4) Figure 6 & 7. Feed aluminum ﬂat bar through bottom of fabric cap.

5) Figure 6. Feed bow through top of fabric cap.

6) Figure 7. Pull cap tight over top rail.

7) Figure 8. Drill holes evenly spaced through aluminum ﬂat bar and attach with 5/16 x 1-1 /2 Type F Torx.

Figure 6

Bow Through

Pocket

Fabric Front Cap

Center Bolts

Figure 7

Pull cap to tighten





Gap

Roll Tarp

Fabric Cap

No Gap

Roll Tarp

Fabric Cap

Double Bow

PowerLock™

FOR GRAIN TRAILERS

Installation Instructions

Step 1c

Aluminum Front Cap: Install Square Nose

1) Figure 9. Measure and make any cut-outs and place

cap on trailer.

2) Attach with 3/8 x 1 Type F HWH Bolts through trough

into top rail.

Index Description Qty

1 Front Cap Square Aluminum 1

2 3/8 x 1 Type F HWH 4

Step 1d

Aluminum Front Cap: Install Shaped to Nose

1) Place cap on front of trailer, center and push lip up

against the trailer.

2) Figure 10. Trace the corner shape of nose onto front

cap and cut-out shape

Index Description Qty

1 Front Cap Aluminum 1

2 Aluminum Strip 1/8 x 3 2

3 3/8 x 1 Type F HWH 4

3) Figure 11. Attach with 3/8 x 1

Type F HWH Bolts through trough

into top rail.

4) Figure 11. Shape the aluminum

strip around the corner of the

trailer, mark and cut to length for

both sides.

5) Figure 12. Weld both pieces to

the front cap.

Radius Corner

Trace Shape

Diagonal Corner

Trace Shape

Offset Corner

Trace Shape

Weld

Shape

Strip

Shape Strip

Figure 10

Figure 11 Figure 12

PowerLock™

FOR GRAIN TRAILERS

Installation Instructions

Step 2a

Fabric Rear Cap: Install Double Bow Bracket or Heavy Duty Bows

30"

Double Bow Bracket

30"

Heavy Duty Bows

10"

Index Description Qty

1 Fabric Rear Cap 1

2 Double Bow or Heavy Duty Bracket 2

Index Description Qty

3 Bows 2

4 3/8 x 1 Type F HWH 8

Figure 13

Figure 14

Hardware to Mount to Sideboards

Index Description Qty

5 5/16 X 2-1/2 CARRIAGE BOLT 8

6 5/16 FLAT WASHER 8

7 5/16 LOCK WASHER 8

8 5/16 HEX NUT 8

Figure 15

Install Double Bow Bracket to Sideboards

1) Figure 13. Measure and mark 30" from the outside of the tailgate and 10" towards the rear from the previous

mark.

2) Figure 14. Clamp ﬁrst pocket of double bow bracket centered on mark on top rail.

3) Figure 14. Position bracket and bow as shown to reduce tarp wear.



4a) Figure 13. Attach with 3/8 x 1 type F HWH bolts.

4b) Figure 15. Attach with 3/8 x 2-1/2 carriage bolts.



PowerLock™

FOR GRAIN TRAILERS

Installation Instructions

Center Bolts

Bow Through

Pocket

Tail

Fabric Rear Cap

Figure 16

5) Figure 16. Feed bow through top of fabric cap and install on trailer.

6) Figure 17. Pull cap tight when securing with Latch Plate or Roll Stop.

No Gap

Roll Tarp

Fabric Cap

Figure 17

Gap

Roll Tarp

Fabric Cap

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