OWNER'S MANUAL Installation Instructions and Parts List READ THIS ENTIRE MANUAL PRIOR TO INSTALLATION Aero Industries, Inc. Attention Dealers: Please give these instructions to the customer when the product is delivered. Indianapolis, IN Omaha, NE Streetsboro, OH R
Three kinds of special explanations will appear in these instructions. Be sure to read and follow them. WARNING: Possible danger to the operator or bystander. The operator or bystander could be injured if you ignore this information. CAUTION: Risk to the product. If you ignore this information the Product or the Vehicle could be damaged. NOTE: Contains additional information about a feature or step critical to the installation of this product. TOOLS REQUIRED FOR INSTALLATION Air or Electric Drill 9/16" Drill Bit 3/4" Open End or Box Wrench 3/4" Socket Air or Electric Impact Wrench Torque Wrench Hammer 24" Square Welder (If necessary to Install Stake Pockets) WARNING: This product meets D.O.T. standard #393.106(d) (1) for its published load rating when installed in strict accordance with these instructions and the hardware specified. Any modifications to this product, substitutions of specified hardware or failure to follow these instructions, WILL void the load rating and may result in injury or death. TRAILER PREPARATION 1. Be sure that the bulkhead you are installing is the correct size and width to fit your flatbed application. 2. Make sure there is a flat, clean surface where the bulkhead bottom rail will meet the trailer top rail. Grind down any welds on the trailer top rail which will create an uneven surface. 3. A trailer stake pocket MUST BE available for the leg of the bulkhead to rest in. For a 10" wrap bulkhead, the center of the pocket must be 10-1/2" from the front of the trailer. For a 22" wrap bulkhead, the center of the pocket must be 22-1/2" from the front of the trailer. Failure to locate a pocket around the leg of the bulkhead WILL void the DOT rating. (See Step 1, Paragraph 3 on Page 3) 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. Aero Warranty Aero Products come with a one year warranty on all parts. It's another example of our on going commitment to customer satisfaction and quality. 1
STEP 1 - Installing the Bulkhead 1. Check your hardware package against the drawings shown to ensure the right size and quanity. All hardware should be Grade 8 and Zinc coated. Hardware Package P/N 0611-960132 3-1/2" Bolt HHCS (Qty. 4) 1/2"-13 1-1/2" Bolt HHCS (Qty. 2) 1/2"-13 Washer Flat (Qty. 6) 1/2" 1/2" 1/2"-13 Washer Lock (Qty. 12) Nut Hex (Qty. 6) WARNING: The legs of the bulkhead must be installed into a stake pocket. Failure to do so will void the DOT rating. NOTE: Stake pockets may be ordered from Aero Industries, Inc. if required. WARNING: Attempting to lift the bulkhead without a lifting device may cause personal injury to the installer. NOTE: Before drilling holes to mount the bulkhead across the front, be sure that there are no electrical or air lines underneath that will be damaged and that there is sufficient clearance on each side of the fifth wheel plate. Figure 1 1/2"-13 x 1-1/2" Bolt 1/2"Flat Washer 1/2"Lock Washer Aero Industries, Inc. 1/2"-13 Nut 12" Approximate 2
Aerolite Wraparound Bulkhead DOT Models 2. See Figure 1. Drill four 9/16" holes through the bottom plate of the bulkhead and the top wall of the trailer front rail using the recommended spacing. Bolt the bulkhead to the trailer using the 1-1/2" bolts, flat washers, lock washers, and hex nuts. NOTE: Do not tighten nuts completely at this time. 3. See Figure 2. If there was not a stake pocket on the trailer to accept the leg of the bulkhead, drive one between the bulkhead stake and the trailer rub rail until it is square with the top rail and positioned 1/4" below the top surface. Be sure that the bulkhead stake is not binding the pocket. NOTE: Make sure that all areas to be welded are clean and that bare metal is exposed before any welding is done. Figure 2 Weld Stake Pocket to Flatbed Along All Indicated Surfaces 1/4" Weld 4. Weld the stake pocket to the siderail to fix its position. Make sure that the bulkhead stake is square (90 ) to the flatbed siderail. Prime and paint the stake pocket and welds if necessary. 3
Aerolite Wraparound Bulkhead DOT Models 6. See Figure 3. Drill a 9/16" diameter hole through the rub rail, stake pocket, stake, and flatbed siderail on each side of the trailer. Install and tighten the 3-1/2" bolts, flat washers, lock washers, and nuts. Figure 3 1/2"-13 x 3-1/2" Bolt 1/2"-13 Nut 1/2"Flat Washer 1/2"Lock Washer 7. Tighten the 1-1/2" bolts at the four locations on the front of the bulkhead. CAUTION: Torque all the bolts to 125 foot-pounds using a torque wrench. 8. Run a bead of clear silicone between the flatbed top rail and the bottom of the bulkhead to achieve a water tight seal. (Silicone not furnished) 1. Be sure that all fasteners are kept tight to proper torque specifications. How to Maintain the Wraparound Bulkhead 2. Inspect for load shift damage and weld cracks. Reweld and grind as required. Aero Industries, Inc. R INDIANAPOLIS, IN. - 4243 Bradbury Ave., Indianapolis, IN 46241-800-535-9545 - FAX: 317-244-1311 OMAHA, NE. - I-80 & Highway 50 South, Omaha, NE 68137-800-535-9545 - FAX: 402-895-6129 STREETSBORO. OH. - 8540 State Route 14, Streetsboro, OH. 44241-888-237-2262 - FAX: 330-626-3277 Aero Kit - BURLINGTON. ON. - 5499 Harvester Road, Burlington, ON. L7L 5V4-800-465-8277 - FAX: 905-335-8499 Aero Industries, Inc. 0930-861527 08/27/2008 Rev. C 4