Easy Cover. Installation Instructions. Attention Dealers: Please give this owners manual to the customer when the product is delivered.

Transcription

1 Serving the Truck & Trailer Industry Since 944 Easy Cover Attention Dealers: Please give this owners manual to the customer when the product is delivered. Call Indianapolis, IN Omaha, NE Streetsboro OH

2 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 a Installing Tarp Housing Inside Cab Shield b 6-7 Installing Tarp Housing with Trailer Mounting Brackets c Roll-up Bar Installing Manual Fixed Roll-up Bar a 9 Installing Electric Motor and Fixed Roll-up Bar b 0 Installing Manual Adjustable Roll-up Bar c Installing Electric Motor and Adjustable Roll-up Bar d Sprocket, Crank, Chain, and Chain Covers Installing Sprocket 3a 3 Installing Manual Crank Assembly 3b 3 Installing Chain and Chain Cover(s) 3c 4 Electrical Installing Standard Electrical Controls with Rocker Arm Switch 4a -6 Install and Wire Motor for Semi-trailer Truck 4b 7 Install Interior Cab Rocker Switch for Semi-trailer Truck 4c Wiring Diagram for Lead & Pup with Contactors Mounted on Tractor 4d 9-0 Wiring Diagram for Lead & Pup with Contactors Mounted on Trail 4e Installing the Optional Electrical Controls with Rotary Switch 4f -3 Spring Assemblies Installing Undermount or Flange Mounted Spring Assembly a 4 Installing Underbody Spring Assembly b Installing Undermount or Flange Mounted Spring Assembly c 6-7 Installing PowerPack Spring Assembly d -30 End Fittings & Lower Swing Arms Installing End Fitting and Steel Lower Swing Arm 6a 3 Installing End Fitting and Aluminum Lower Swing Arm 6b 3 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 3-36 Attach Tarp to Roll-up Bar Installing Tarp to Roll-up Bar, Roll Under (Standard) a 37 Installing Tarp to Roll-up Bar, Roll Over (Optional) b 37 Easy Cover Electric Model Operation Instructions 3 Maintenance Recommendations 3 Easy Cover Manual Model 39 Operation Instructions 39 Maintenance Recommendations 39

3 * 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. Label part# * 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. 3

4 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 Awl Hammer /" hole saw Drill Bits:.7" (F drill), 9/3",.36" (O drill), 3/3", 7/3" Sockets: 7/6", 9/6" Open End or Box Wrenches: 7/6", 9/6", 3/4" Vice Grip Pliers ( pair) Electric or Air Drill 4

5 Step a Installing End Plates and Wind Deflector End Plates (DS & PS) Wind Deflector 3 3/-6 x Carriage Bolts 4 4 3/-6 x Hex Bolt 6 3/-6 Nylon Hex Nut 0 ) See Figure. Install 3/-6 x carriage bolts (3) and 3/-6 Nylon hex nuts (4) in the driver's side and passenger's mounting plates (). Do not tighten. ) Slide end plates () 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 () to a minimum. 3 3) See Figure. 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 3/3" holes through the top rail where square holes reside. ) Secure driver's side end plate with 3/-6 x hex bolt (), 3/ lock washer (6), Figure and 3/-6 Nylon hex nut (7). 6) Repeat Steps 4 and for passenger's side end plate (). Aligning Notch 7) Tighten nuts on carriage bolts holding the wind deflector (). Square Holes referred to in Step 4 Figure Driver's Side Shown

6 Step b Installing Tarp Housing inside Cab Shield Tarp Housing Mounting Bracket 4 3 Rubber Bushing 4 4 /-3 x Hex Bolt GR / Flat Washer 6 / Nylon Hex Nut ) See Figure 3. Hold mounting bracket () 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. ) 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 () 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 /" (once mounted) to the left or right if measurements are not exact. Drill marked holes using 7/3" drill bit. Lip Mark in center of slot "C" 3/4" Use angle as template Distance same on both sides Inside radius Drop clearance "B" Figure 3 "A" D.S. View Figure 4 6

7 3) See Figure. Attach mounting bracket () to cab shield using /-3 x hex bolt (4), / flat washer (), and /-3 nylon hex nut (6). 4) See Figure. Set housing with rubber bushings (3) onto mounting bracket () and fasten securely through slotted holes /-3 x hex bolt (4), / flat washer (), and /-3 nylon hex nut (6). Rubber bushings should compress to about 3/" to /". 4 3/" - /" 3 D.S. View Figure

8 Step c Installing Tarp Housing with Trailer Mounting Bracket Tarp Housing Mounting Bracket Trailer 3 Rubber Bushing 4 4 /-3 x Hex Bolt GR / Flat Washer 6 / Nylon Hex Nut ) See Figure 7. Turn tarp housing () upside down and position mounting bracket trailer () " in from each end and flush with the back of the tarp housing () (not the end plates). Keeping brackets straight and parallel with end plates, mark holes through brackets ) Drill marked holes using 7/3" drill bit. 3) See Figure 6. Attach mounting brackets with rubber bushings (3), /-3 x hex bolt (4), / flat washer (), and / - 3 nylon hex nut (6). Tighten until bushings compress to approximately 3/" to /". 4) See Figure 7. Hold housing up to trailer firmly, center on trailer and trace holes in mounting brackets. Drill marked holes using 7/3" drill bit. ) Attach with /-3 x hex bolt (4), / flat washer (), and /-3 nylon hex nut (6) /" - /" Figure 6 Figure 7

9 Step a Installing Manual Fixed Roll Up Bar Fixed Manual Roll Up Bar ) See Figure. Unbolt and remove the shafts from both ends of fixed manual roll up bar (). ) On the driver's side align the fixed manual roll up bar () with the bearing, insert the shaft with the keyway through the bearing. 3) Bolt the shaft using the /4-0 x /4 hex bolt and /4-0 nylon hex nut remove in step. 4) On the passenger's side align the fixed manual roll up bar () with the bearing and insert shaft through the bearing. ) Bolt the shaft using the /4-0 x /4 hex bolt and /4-0 nylon hex nut remove in step. Shaft with Keyway /4-0 x /4 Hex Bolt /4-0 x /4 Hex Bolt /4-0 Nylon Hex Nut /4-0 Nylon Hex Nut Figure 9

10 Step b Installing Electric Motor and Fixed Roll Up Bar Motor RA/SWB Fixed Electric Roll Up Bar 3 Motor Cover 4 /6- x 7/ FHCS 3 #0 x Self-drilling Pan Head 3 Figure 0 ) See Figure 9. Fasten motor RA/SWB () to the end plate or tarp housing with three /6- x 7/ FHCS (3). ) With screws provide with the motor attach the cover to the motor. (Cover will need to be removed for wiring.) 3)See Figure 0. When installing on a tarp housing use the motor cover (3) with two #0 x self-drilling pan head screws (). 4) See Figure 9. Unbolt and remove the shaft from end of fixed electric roll up bar (). ) One end does not have a shaft. Remove the nut and bolt from that end. Insert end onto shaft of motor RA/SWB (), 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 () with the bearing and insert shaft through the bearing. 7) Bolt the shaft using the /4-0 x /4 hex bolt and /4-0 nylon hex nut remove in step 4. Cover Screws Motor Cover /4-0 x /4 Hex Bolt /4-0 x /4 Hex Bolt /4-0 Nylon Hex Nut /4-0 Nylon Hex Nut 4 Figure 9 0

11 Step c Installing Manual Adjustable Roll Up Bar Adjustable Manual Roll Up Bar /4-0 x /4 Hex Bolt 3 /4-0 Nylon Hex Nut ) 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. ) 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. With passenger's end of roll up bar within /4" - /" of bearing drill two.7" (F drill) holes thru both tubes as shown. ) Secure outside tube to inside tube with two /4 x /4 Hex Bolts from hardware pack. Flush against bearing " diameter (F Drill) Thru both tubes places Figure 3

12 Step d Installing Electric Motor and Adjustable Roll Up Bar Motor Winch "B" Adjustable Electric Roll Up Bar 3 /6- x / FHCS 3 4 /4-0 x /4 Hex Bolt /4-0 Nylon Hex Nut ) See Figure. Fasten Motor Winch "B" () to driver's side end plate with /6- x / FHCS (3). ) 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 (), 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. ) 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 /4" - /" of bearing drill two.7" (F drill) holes thru both tubes as shown. 7) Secure outside tube to inside tube with two /4 x /4 Hex Bolts from hardware pack. Cover Screws Motor Cover Hex nut and bolt secures roll up bar to motor shaft.7" diameter (F Drill) Thru both tubes places Figure 4

13 Step 3a Installing the Sprocket Sprocket Key ) See Figure 3. Slide the sprocket () 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. ) Lightly tap the key () 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 (). Do not over tighten. Step 3b Installing Manual Crank Assembly Figure 3 Crank Assembly 3/ x Self Tapping Hex Bolt ) Remove the cover (if installed) on the crank assembly and lay cover aside until after the chain is installed. ) See Figure 4. 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 3/3" 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. Figure 4 3

14 Step 3c Installing the Chain and Chain Cover(s) Chain Master Link 3 Crank Cover Aluminum 4 Chain Cover Lower Aluminum Guard Mounting Brackets 6 6 #4 x / Self Drilling Screw 6 7 #4 x Self Drilling Screw 6 Crank Handle ) See Figure. Wrap chain () around both sprockets and remove the excess links. ) Wrap the shortened chain the sprockets and fasten the two ends with the master link (). Aluminum Cover 3) See Figure 6. Install crank cover lower aluminum (4) with the guard mounting brackets () to the body with #4 x / self drilling screws (6) and #4 x self Figure drilling screw (7). 4) See Figure 7. 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 " Figure 6 Figure 7 4

15 Step 4a Installing the Standard Electrical Controls with Rocker Switch Reverse DC Contactor DC Contactor Cover 3 Switch Rocker Assy for DC Contactor 4 Circuit Breaker 40 Amp * Wire #6 Duplex Varies *6 Wire #4ga 3 Conductor Type SJ 0' 7 Wire End #6 x /4 Ring Term. Wire End #6 x 3/ Ring Term. 9 Wire End #6 x #0 Screw Ring Terminal 0 Wire End #4 x /4 Push on 6 Wire End #4 x 3/ Ring Term. 0-3 Hex Nut 3 /4 x 3/4 Pan Head Phillips 4 /4-0 x Hex Head Bolt /4-0 x Hex Head Bolt 6 /4 Flat Washer 7 /4-0 Nylon Hex Jam Nut 4 /6-4 Hex Nut 4 9 /6 Lock Washer 4 0 Clamp Metal Loom Plastic Coated Wiring Diagram Reverse Contactor ) Open and layout all electric hardware parts. ) 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 9/3" holes. 3) Mount rocker switch (3) using () /4-0 x Hex bolts (4), (4) /4 flat washers (6), and () /4 Nylon hex nuts (7). 4) Find a secure location at or near the back of the cab to mount the reversing DC contactor (). Mount the reversing DC contactor () using () /4-0 x hex bolts (), (4) /4 flat washers (6), and () /4-0 Nylon hex nuts (7). Do not tighten at this time. ) 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. Figure

16 6) Secure the #6 wire () along the vehicle frame using clamp metal looms (0) and /4 x 3/4 pan head Phillips (3) 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 (). Wire switch (3) and reversing DC contactor () according to diagram with #4 wire (6). ) Measure distance between battery and reverse DC contactor () run #6 wire () 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. 0) Place the DC contactor cover () on the reversing DC contactor () and tighten the /4-0 bolts and nuts. Figure 9 6

17 Step 4b Install and Wire Motor for Semi-trailer Truck ) Install receptacle at the front of the trailer. Attach the #6 wire to the butt connectors on the receptacle. For End Dumps a) See Figure 0. 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 b) See Figure. Run #6 wire from receptacle up to the motor. Secure all wire with clamps. Figure 0 Figure Schematic 3) Attach #6 wire to motor with /4 ring terminals. 7

18 Step 4c Install Interior Cab Rocker Switch for Semi-trailer Truck Locate Operation/Maintenance Sheet and keep near switch. ) Find a convenient place on the driver's side under the dashboard to mount the rocker switch with /4-0 x " hex bolts Cover Uncover ) Mount reversing contactor outside near back of cab with /4-0 x " hex bolts. 3) Run wire from switch to reversing contactor. Run wire from battery to reversing contactor. Secure all wire with clamps. 4) Connect breaker to battery and secure with zip ties. ) 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.

19 Step 4d Wiring Diagram for Lead & Pup with Contactors Mounted on Tractor Reverse DC Contactor DC Contactor Cover 3 Switch Rocker Assy for DC Contactor 4 Circuit Breaker 40 Amp Wire #6 Duplex Varies 6 Wire #4ga 3 Conductor Type SJ 0' 7 Wire End #6 x /4 Ring Terminal 4 Wire End #6 x 3/ Ring Terminal 0 9 Wire End #6 x #0 Ring Terminal 0 Wire End #4 x /4 Push on 0 Wire End #4 x 3/ Ring Term. Plug Quick Disconnect Assembly Hex Nut 4 /4-0 x Hex Head Bolt 4 /4-0 x Hex Head Bolt 4 6 /4 Flat Washer 6 7 /4-0 Nylon Hex Jam Nut /6-4 Hex Nut 9 /6 Lock Washer 0 Wiring Diagram Reverse Contactor Tractor Lead Pup Battery + Positive 4 Motor Forward Motor Reverse 7 7 Battery VDC Negative 9 3 T 0 Battery - 0 T Motor Forward Battery T 0 0 T Battery - Motor Reverse Figure 9

20 Figure 3 0

21 Step 4e Wiring Diagram for Lead & Pup with Contactors Mounted on Trailer Reverse DC Contactor DC Contactor Cover 3 Switch Rocker Assy for DC Contactor 4 Circuit Breaker 40 Amp Wire #6 Duplex Varies 6 Wire #4ga 3 Conductor Type SJ 0' 7 Wire End #6 x /4 Ring Term. 4 Wire End #6 x 3/ Ring Term. 9 Wire End #6 x #0 Screw Ring Terminal 4 0 Wire End #4 x /4 Push on 0 Plug Quick Disconnect Assembly Plug Quick Disconnect Assembly Hex Nut 4 4 /4-0 x Hex Head Bolt 4 /4-0 x Hex Head Bolt 4 6 /4 Flat Washer 6 7 /4-0 Nylon Hex Jam Nut /6-4 Hex Nut 9 /6 Lock Washer 0 Wiring Diagram Reverse Contactor Tractor Lead Pup Positive Battery VDC Negative Motor Forward 6 T 0 Battery + Battery - Motor Reverse 0 T Figure 4 7 T 0 6 Motor Forward 7 Battery + Motor 0 T Reverse Battery -

22 Step 4f Installing the Optional Electrical Controls with Rotary Switch Rotary Switch 9 Wire End #6 x /4 Ring Terminal Circuit Breaker 40 Amp 0 Wire End #6 x 3/ Ring Terminal 3 Mounting Bracket /4 x 3/4 Pan Head Phillips 4 Decal Rotary Switch /4-0 x 3/4 Hex Head Bolt Clamp Metal Loom Plastic Coated 3 /4 Flat Washer 4 *6 Wire #6 Duplex Varies 4 /4-0 Nylon Hex Nut 7 Wire Butt Connectors #6 4 Wiring Diagram Wire End #6 x #0 Ring Terminal 6 ) Open and layout all electric hardware parts. ) See Figure. Peel decal (4) and place on the mounting bracket (3). Truck Battery B A B B A Gearmotor /4" x #6 Wire End () A B A Rotary Switch Backview of Rotary Switch Switch Plate Figure 3) Find a convenient place on the driver's side under the dashboard to mount the rotary switch (). Using the mounting bracket (3) as a template, mark and drill two 9/3" holes. 4) Attach mounting bracket (3) using () /4-0 x 3/4 Hex bolts (), (4) /4 flat washers (3), and () /4 Nylon hex nuts (4). ) Remove the switch handle and fasten nut from the rotary switch (). Pass the rotary switch's operating shaft through the hole in the mounting bracket (3) from behind the plate. Replace the nut and tighten it to secure the switch to the mounting bracket. Replace the handle.

23 6) See Figure 6. 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 () and /4 x 3/4 pan head Phillips () 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. ) At the gearmotor attach the wire ends using wire end #6 x /4 ring terminals (9). 9) At the rotary switch fasten #6 x #0 ring terminals () to the ends of wires A and A, at the switch, attach these two ring terminals to the marked terminals of rotary switch. 0) Measure the wiring distance between the rotary switch and truck's battery. If possible, run the wiring along an existing wiring harness. Run wiring to truck"s Battery. 3) Fasten #6 x #0 ring terminals () to the ends of wires B and B, at the switch, connect these ends to the marked terminals on the rotary switch. 4) Separate wire at battery approximately " back. ) See Figure 6. Install a circuit breaker (3) at or very near the battery's positive terminal. Secure circuit breaker in place with a zip tie if possible to prevent movement. ) Cut wire at B and attach circuit breaker using two wire end #6 x #0 ring terminals (). 6) Connect wire B to positive terminal and connect wire B to negative terminal using wire end #6 x 3/ ring termianls. Figure 6 3

24 Step a Installing Undermount or Flange Mounted Spring Assembly Index Description Qty Flange Mounted Spring (driver side) Flange Mounted Spring (passenger side) 3 3/-6 x /4 Hex Bolt Index Description Qty 4 3/ Flat Washer 6 3/-6 Nylon Hex Nut ) Mark the rear edge of the tarp housing or the mounting plate in line with the tarp roll up bar on the driver's side and passenger's side. Mark these points and call them (A). ) Determine where you want the rear of the tarp to be when it fully covers the box. Mark these points and call them (C). 3) See Figure. Find a point at the side of the box that is the same distance from A and C. This is point B, where the spring assembly will be mounted. Mark this point on both sides. 4) Position the driver's side spring assembly () to the point marked on the driver's side (B). Clamp the spring assembly into position centering the mounting plate on point B. The top of the mounting plate should be as high as possible from the bottom of the box. ) See Figure 9. Drill four 3/3" holes using the mounting plate as a guide. 6) Bolt the spring assembly to the box or rail with 3/ - 6 x hex bolts (3), 3/ flat washers (4), and 3/-6 nylon hex nut (). 7) Repeat Steps 4-6 for passenger's side. Figure 7 Figure 3 Figure 9 4

25 Step b Installing Underbody Spring Assembly Index Description Qty Flange Mounted Spring (driver side) Flange Mounted Spring (passenger side) 3 3/-6 x /4 Hex Bolt Index Description Qty 4 3/ Flat Washer 6 3/-6 Nylon Hex Nut 6 Plate Aluminum Cover (optional) ) Mark the rear edge of the tarp housing or the mounting plate in line with the tarp roll up bar on the driver's side and passenger's side. Mark these points and call them (A). ) Determine where you want the rear of the tarp to be when it fully covers the box. Mark these points and call them (C). 3) See figure 30. Find a point at the side of the box that is the same distance from A and C. This is point B, where the spring assembly will be mounted. Mark this point on both sides. 4) See Figure 3. Disassemble spring assembly by loosening set screw at rear of assembly. Pull spring support shaft out from the front of assembly. ) See Figure 3. Place spring assembly housing up underneath dump body aligned at point B. Rest the top edge against the bottom of the dump body. Once in place, trace the holes onto the dump body. 6) Drill four 3/3" holes and the /" hole with a hole saw. 7) See Figure 3. Bolt spring assembly housing to the dump body using 3/-6 x hex bolt (3), 3/ flat washer (4), and 3/-6 nylon hex nut (). If optional plate aluminum cover (6) is used, place it on the outside of the dump body before bolting in place. ) Re-assemble spring assembly. 9) Repeat Steps 4-7 for passenger's side. Figure 30 Figure Figure 3

26 Step c Installing PowerPack Spring Assembly STEP ) Locating the position to install the spring assembly STEP ) Marking the pilot holes Use mounting holes to mark the hole location. Repeat for opposite side of trailer. Figure 33 STEP 3) Drilling the mounting holes Using a 9/6" drill bit, drill the mounting holes. Repeat for opposite side of trailer. Marker Mounting holes Point B 9/6" drill bit Mark and drill both Driver Side and Passenger Side holes

27 STEP 4) Mount the spring assembly Dump Body Optional Rear Mounting Plate Flat Washer Lock Nut Flat Washer Lock Nut Flat Washer Hex Bolt STEP ) Attach the Optional Rear Mounting Plate 7

28 Step d Installing PowerPack Spring Assembly STEP ) Locating the position to install the spring assembly Figure 34 STEP ) Marking the pilot holes Use pilot holes to mark the hole location. Repeat for opposite side of trailer. STEP 3) Drilling the mounting holes Using a 9/6" drill bit, drill the mounting holes. Repeat for opposite side of trailer. Point B Marker Pilot hole 9/6" drill bit Mark and drill both Driver Side and Passenger Side holes

29 STEP 4) Installing Drive Side Mounting Bracket Index Description Qty Mounting Brackets /-3 x " Hex Bolt 4 3 / Flat Washer 4 4 /-3 Nylon Hex Nut 4 On the driver side rotate the mounting bracket to the position shown and attach using the /-3 X " bolts, / flat washers, and /-3 nylon hex nuts. Front Tailgate Driver Side of Dump Body STEP ) Installing Passenger Side Mounting Bracket On the passenger side rotate the mounting bracket to the position shown and attach using the /-3 X " bolts, / flat washers, and /-3 nylon hex nuts. Tailgate Front Passenger Side of Dump Body 9

30 STEP 6) Assemble and install the Drive Side PowerPack spring. On the mounting bracket shaft, place in this order: Description Qty 9 /4" Flat Washer PowerPack Casting half 7 Plastic Insert 'A' 6 Spring PowerPack Spiral 3 Plastic Insert 'B' PowerPack Casting half 9 /4" Flat Washer 0 /4 External Retaining Ring A A Front Neck Tailgate Spring hook closets to the neck must be facing down. Driver Side of Dump Body STEP 7) Assemble and install the Passenger Side PowerPack spring. On the mounting bracket shaft, place in this order: Description Qty 9 /4" Flat Washer PowerPack Casting half Plastic Insert 'B' 6 Spring PowerPack Spiral 3 7 Plastic Insert 'A' PowerPack Casting half 9 /4" Flat Washer 0 /4 External Retaining Ring Tailgate Neck Spring hook closets to the neck must be facing down Front B B Passenger Side of Dump Body 30

31 Step 6a Installing the End Fitting and Steel Lower Swing Arm End Fitting /4" Spring Pins 4 3 Swing Arm Lower Steel 4 /6- x /4 Hex Bolt 4 /6- Nylon Hex Jam Nut 4 ) See Figure 39. Place swing arm lower (3) onto casting and secure with /6- x /4 hex bolt (4) and /6- nylon hex jam nut (). 4 ) See Figure 39. Place a end fitting () on the driver's side tension spring assembly shaft so it is facing the rear. 3) See Figure 39. Drive /4" spring pins () into the end fitting () and thru the shaft. Figure ) Repeat for opposite side. Facing Down Facing Up Figure 40 3

32 Step 6b Installing the End Fitting and Aluminum Lower Swing Arm End Fitting /4" Spring Pins 4 3 Swing Arm Lower Aluminum 4 /6- x HWH Type F 4 ) See Figure 4. Place a end fitting () on the driver's side tension spring assembly shaft so it is facing the rear. See Figure ) See Figure 4. Drive /4" spring pins () into the end fitting () and thru the shaft. 4) Repeat for opposite side. Figure 4 ) See Figure 4. Place swing arm lower aluminum (3) onto casting and secure with /6- x HWH Type F (4). Facing Down Facing Up Figure 4 3

33 Step 6c Installing Aluminum Lower Swing Arm on PowerPack Spring Assembly Swing Arm Lower Aluminum 3/-6 x HWH Type F 4 ) See Figure 43. Slide swing arm lower aluminum () onto powerpack spring assembly. ) See Figure 43. Secure with 3/ - 6 x HWH type F (). 3) Repeat for opposite side. Facing Up Facing Down Figure 43 33

34 Step 7a Installing Steel Cross Arm and Connecting Arms Tarp Cross Arm 3 Connecting Arm D.S. 4 Connecting Arm P.S. 4" Tarp-Centering Springs 6 /4-0 x / Hex Bolt 7 /4 Eye Bolt /4 Keps Nut 4 9 Armguard rubber bumpers 0 Mild soap and water (optional) na ) See Figure 44. Feed the cross arm () through the pocket in the end of the tarp (). 9 ) Slide both connecting arms (3 & 4) onto the cross arm. 3 3) Raise the swing arm to the top of the tailgate and slide the ends of the connecting arms (3 & 4) over 6 the swing arm. 4" 7 4) Square the tarp and the rear cross bar with the top of the tailgate. Swing Arm ) See Figure 44. Drill a 9/3" hole through each swing Figure 44 arm using the holes in the connecting arms as a guide. 6) Fasten the swing arms to the connecting arms with /4-0 x / hex bolts (6) and /4 Keps nut (). 7) Center the tarp from side to side on the rear cross bar. ) See Figure 44. Measure 4" from the edge of the tarp on both sides. Drill 9/3" horizontal hole through the connecting arm and the cross arm. DO NOT drill through the tarp. 9 9) See Figure 4. Before installing eyebolts (7) and springs (), slide rubber bumper (9) over each end of cross arm and Inside Edge position inside of notch in tarp. Position bumpers to rest on Tail Gate tailgate. Figure 4 0) Fasten the arms with eye bolts (7) and /4 Keps nuts (). ) Attach the spring () to the grommet in each corner of the tarp and eye bolt (7). Crimp the ends of the springs. 34

35 Step 7b Installing Upper Swing Arms and Cross Arm Tarp Cross Arm 3 Upper Swing Arm 4 Arm Casting Rubber Bumper 4 6 3/-6 x 3/4 Hex Bolt 4 7 /4-0 x Hex Bolt 4 3/-6 x Hex Bolt 9 3/-6 x 3 Hex Bolt 0 /4-0 Nylon Hex Jam Nut 6 3/-6 Nylon Hex Nut 4 /4-0 x / Eye Bolt 3 4" Tension Spring 4 Plug End ) See Figure 46. Insert arm casting (4) into upper swing arm (3) and secure with 3/-6 x hex bolt () and 3/-6 Nylon hex nut (). Repeat for second arm casting (4) and upper swing arm (3). ) See Figure 46. Slide upper swing arm (3) into lower swing arm and insert 3/-6 x 3/4 hex bolts (6) into the tapped holes of the lower swing arm. Repeat on opposite side. 3) Roll out tarp () in bed of truck. 6 Make sure the pocket is at the 3 rear of the truck ) Insert cross arm () through the 9 pocket in the tarp () at the tail gate, center and place on the bed. 7 ) Insert /4-0 x hex bolt (7) into each rubber bumper and attach /4-0 Nylon hex jam nut 0 (0). Figure ) Slide rubber bumpers () onto 4 each side of the cross arm (). 7) Lift one swing arm and insert cross arm () into arm casting (4). Insert far enough /" - 3/4" so opposite swing arm can be lifted and inserted through the opposite arm casting (4). ) See Figure 47. Adjust cross arm () on one side to extend /"-3/4" beyond arm casting (4). Figure 47 3

36 9) With the cross arm () resting on the tail gate drill a /4" hole through the tube using the hole in the arm casting (4) as a guide. Secure with 3/-6 x 3" hex bolt (9) and 3/-6 nylon hex nut () 0) See Figure 4. Position swing arm to be parallel with the bed. While maintaining that position, slide the opposite swing arm on the cross arm () until it is parallel with the bed. ) Repeat 9. )See Figure 4. Cut excess cross arm () which extends /"-3/4" beyond arm casting (4). 3) Insert Plug Ends () into each end of cross arm (). 4) Position one set of rubber bumpers (4) to sit on tailgate and one set to hit end plates or tarp housing and tighten bolts. OPTIONAL: See Figure 46. Use eyebolt and spring to keep tarp centered. / - 3/4 Cut Off Figure 4 36

37 Step a Installing the Tarp to the Roll Up Bar, Roll Under (Standard) Tarp /4-0 x / Pan Head 6 3 /4 Square Nut 6 4 /4 Split Lock Washer 6 ) See Figure 49. Pull the loose end of the tarp () under the roll up bar, winding from the underside. Make sure the tarp is centered from side to side. ) Mark the tarp roll up bar for fastener placement using the grommets in the tarp as a guide. 3) Secure tarp () with /4-0 pan head Phillips (), /4-0 square nuts (3), and /4 split lock washers (4). Winding Direction 4 Tarp Eyelet 3 Tarp Roll-up Bar Driver s Side End View Step b Installing the Tarp to Roll Up Bar, Roll Over Optional) Figure 49 Tarp /4 Pan Head 6 3 /4 Square Nut 6 4 /4 Split Lock Washer 6 ) See Figure 0. Pull the loose end of the tarp () over the roll up bar, winding from the topside. Make sure the tarp is centered from side to side. ) Mark the tarp roll up bar for fastener placement using the grommets in the tarp as a guide. 3) Secure tarp () with /4-0 pan head Phillips (), /4-0 square nuts (3), and /4 split lock washers (4). Winding Direction 4 Tarp Eyelet 3 Tarp Roll-up Bar Driver s Side End View Figure 0 37

38 Direction switch operates depends on how it is wired. Easy Cover Electric Model Operation Instructions Push to cover unit and release when fully covered. Push to uncover unit and release when fully uncovered. Aero Industries recommends a weekly inspection of the following items: Replace all worn or broken parts immediately. Repairs must ONLY be made after proper instruction. Inspect Tarp for wear and tears. Maintenance Recommendations Inspect Arms for damage (cracked, dented or bent). Nuts & Bolts: Make sure all mounting bolts and nuts are in place and tight and that no parts are worn or damaged. Bearings: Pull the shafts from side to side and in and out. If there is excessive play, replace the bearings. Apply penetrating oil lightly as needed. Springs: Examine springs for breakage or distortion. Apply a light coat of penetrating oil to tension springs as needed. Electrical Connections: Check all electrical connections and tighten any loose connections. Safety Labels: Clean labels with soap and water. Replace if damaged and/or difficult to read. Replacement Parts and instructions may be obtained from your Aero dealer or by contacting Aero Industries. 3

39 Easy Cover Manual Model Crank handle is only used for uncovering. Remove and store crank handle when not in use. Uncover Unit (Standard Crank) Crank handle is only used for uncovering. Remove and store crank handle when not in use. Uncover Unit (Reverse Crank) Cover Unit Pull brake handle down quickly to brake position Maintenance Recommendations Inspect Tarp for wear and tears. Inspect Arms for damage (cracked, dented or bent). Bearings: Pull the shafts from side to side and in and out. If there is excessive play, replace the bearings. Apply penetrating oil lightly as needed. Springs: Examine springs for breakage or distortion. Apply a light coat of penetrating oil to tension springs as needed. Fasteners: Make sure all mounting bolts and nuts are in place and tight and that no parts are worn or damaged. Chain: Check the chain tension, that links move smoothly, and make sure the master link is on. Lubricate the chain regularly with penetrating oil. 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 difficult to read. Replacement Parts and instructions may be obtained from your Aero dealer or by contacting Aero Industries. 39

40 Call INDIANAPOLIS, IN Indianapolis, IN FAX: OMAHA, NE Omaha, NE FAX: STREETSBORO, OH Streetsboro, OH FAX: Aero Industries, Inc. Easy Cover and the Claw are trademarks of Aero Industries, Inc. The Claw Patent Pending. Covered by one or more of the following patents in the U.S.,9,69;,74,6; 6,34,6; 6,3,790; 6,33,; 6,367,6; 6,47,6; 6,474,79; 6,36,36; 6,7,; 6,7,9; 6,7,97; 6,637,00; 6,7,49; 6,76,73; 6,94,74; 7,7,70;,0,97;,0,9;,67,46;,444,06;,0,3 and others pending in Canada,073,74;,074,607;,394,047;,403,47;,403,44;,47,09;,499,6;,6,379; 6990 and other patents pending. Aero Industries, Inc /3/4 Rev. I