Serving the Truck & Trailer Industry Since 1944 Additional Instructions for 6" Drop Attention Dealers: Please give this manual to the customer when product is delivered. Call 800-535-9545 www.aeroindustries.com Indianapolis, IN Omaha, NE Kent OH
Note: These are the steps that are different for the 6" drop. Installation Directory Item Step Page Important Safety Information 3 Trailer Configuration & Tools Required 4 Trailer Preparation (before installation) 5 Prepare Front Assembly for Installation 1a 6 Install Front Assembly 1b 7-8 Install Rear Idlers 3 9-10 Install Tarp on Trailer 8a 11 Install Tarp on Ground (Optional) 8b 12-13 Set the Power Bow Location and Attach Tarp to Power Bow 8c 14 Attach Tarp to Wind Deflector 8d 14-15 2
This manual explains how to install and maintain the Crank-N-Go 3 tarp system. Important Safety Information NOTE: Contains information critical to the installation or operation of this product. 3
Trailer Confi gurations Preparation Lifting Device Marker or Felt Pen Tape Measure Hammer Vice Grip Pliers (2 pair) Razor Knife Electric or Air Drill Straight Edge C - clamp (2) Tools Required for Installation Drill Bits:.257" (F drill), 9/32",.316" (O drill), 13/32", 17/32", 9/16" Sockets: 7/16", 9/16" Open End or Box Wrenches: 7/16", 9/16", 3/4" Black Electrical Tape 1/4" cable x 5' long (2 pcs.) 1/4" cable clamps (4) 2" x 4" x 8' boards (2) Sheave for Cable Sheave for Cable Trailer Width System Width Cable Center SYSTEM WIDTH 4
Trailer Preparation (before installation) The Crank-N-Go 3 must be able to slide on the top rail from the rear of the dump all the way to the front. Also all components must be able to mount without interference. Check the bulkhead and the front corners for: Obstructions that may interfere with mounting the front assembly. Angled or irregular surfaces that may require custom mounting brackets or hardware. Check to see if the bulkhead is square with the sides. Shims may be required so front assembly is square with sides. Check top rail for: Is flat and continuos (no gaps) from the front to the rear (including cab shield) If tapered front to back, taper must be continuous. Nothing preventing the bows (bolts, brackets, or pins) from traveling from the front to the rear. Check the rear of the trailer for: There are no obtrusion from properly mounting the rear idler. Flat surface to mount the rear idler Check sides of the trailer for: Rear idler can be mounted so the sheaves (pulleys) are the same width as the ones on the front assembly. Idler location will not interfere with the lift gate or swing of the tailgate. Protrusions that would interfere with the operation of the cables and ant-lift. Make required modifications before installing unit. Obtain special hardware that may be needed to mount components. Make or purchase custom brackets needed to mount components securely. Top rail is flat and continuos (no gaps) from front to rear (including cab shield). Custom brackets may be needed for mounting. Eliminate Gaps 5
Note: The bows and tarp can be installed before or after installing the front assembly and the rear idlers. Step 1a Prepare Front Assembly for Installation Top rail even height Raised Bulkhead This is to prepare the front assembly to be attached to the bulkhead of the trailer. Note: Hanger brackets need to be removed when the top rail on the front of the trailer is higher than the top rail on the sides like a raised bulkhead. (See graphics on following pages) Electric Manual Square Front without extension Extension without hanger brackets Square Front without extension Extension without hanger brackets Hanger Qty - 4 Hanger Qty - 4 Tarp Clamp Tension Cable Bracket Remove Front Bracket Extension on square trailers Tension Cable Bracket Front Bracket Extension Adjust all the way out Tension Cable Bracket Front Bracket Extension Used on radius trailers Adjust to fit trailer Equally Spaced Move Brackets to sit on flat face of Bulkhead Hanger 6
Step 1b Install Front Assembly Square bulkhead Top rail the same front and sides. 1a) Figure 1-1. Using lifting slings, place Front Assembly in position with hanger brackets sitting on the top rail. A square bulkhead does not need the mounting bracket extension. Raised bulkhead Top rail is NOT the same front and sides. 1b) Figure 1-2. Using lifting slings, place Front Assembly in position without hanger brackets and align Tension Cable Bracket with top of rail. Figure 1-1 Figure 1-2 NOTE: Front Assembly shown with hanger brackets removed. Equal Spacing 2) Figure 1-3. Center Front Assembly so there is equal spacing on either side of trailer. 3) Figure 1-4 & 1-5. The drive sheave should be 3/4" - 7/8" from the top rail. The top of tension bracket is NOT flush with top rail. Hanger brackets places the unit at the correct height. NOTE: TOP of drive sheaves must be 3/4" to 7/8" BELOW top rail surface. Check both sides. 3/4-7/8 Figure 1-3 Top of Tension Bracket is NOT flush with the top of the top rail. It sits above the top rail. Drive Sheave Figure 1-4 Figure 1-5 7
Step 1b (cont.) 4) FIGURE 1-7. Verify Front Assembly is on center, square to running surface, straight and at correct height. NOTE: Shim front assembly out as needed to maintain straightness. Drive shaft must not be installed bent. Do NOT cause Front Assembly to bow. 90 90 Figure 1-7 5) Verify side brackets are parallel to top rail running surface, then remove 2 x 4 x 8 lumber if used. 6) FIGURE 1-8. Adjust mounting brackets against the side of the dump body and tighten bolts. 7) Figure 1-9. Install side brackets with bolts, both sides of trailer. Mounting Brackets Adjust against dump body Figure 1-8 21/64" drill into dump body 13/32" clearance hole in extension 13/32" drill into dump body 3/8 X 1-1/2" TYPE F 3/8 Flat Washer 3/8-16 X 7" Hex Bolt 3/8-16 Hex Nut Nylon Insert 3/8 Flat Washer Figure 1-9 Shim 8) Figure 1-10. Install Hanger brackets with Bolts. 3/8-16 X 7" Hex Bolt 3/8 X 1-1/2" TYPE F or 3/8-16 Hex Nut Nylon Insert 3/8 Flat Washer Figure 1-10 STEP 2a STEP 2c 8
Step 3 Install Rear Idler Avoid allowing the rear idler to extend past the tailgate or interfere with the operation of the tailgate in any way (like 2-way tailgates). 1) Positioning the Rear Idler. No obstructions on the top rail: set the back edge flush with the rear most feature of the trailer (tailgate for example). Flush and parallel Flush Obstruction on top rail: set the front of the idler flush with the obstruction. The power bow will stop 2" short of this point. Front flush with obstruction Gap in top rail: set the front of the idler 2" behind where the gap starts. Flush and parallel 2 Power Bow Extender: Front of idler is 8" from back of tailgate. 7" idler will extend past the tailgate 4". This could allow the rear idlers to be hit and damaged. 2) Position rear idler flush and parallel with top rail and mark hole locations. Power Bow 8.00 Power Bow Extender Flush Tailgate 9
Step 3 (cont.) NOTE: Mount rear idler with 4 bolts thru, 2 bolts thru & 2 taping or 6 taping bolts. 4) Figure 3-1. Bolt Idler Angle Bracket to trailer both sides of trailer. 21/64" drill into dump body 13/32" clearance hole in extension 13/32" drill into dump body 3/8 X 1-1/2" TYPE F or Figure 3-1 3/8-16 X 7" Hex Bolt 3/8-16 Hex Nut Nylon Insert 3/8 Flat Washer 5) Figure 3-2 & 3-3. Set sheave (pulley) center to center measurement to match system width and tighten bolts. SYSTEM WIDTH SYSTEM WIDTH Align sheaves and tighten bolts Figure 3-2 6) Figure 3-3 & 3-4 Verify Idler Assemblies are at correct width. 7) Figure 3-4 Verify rear Idler Pulleys are equal distance from front Drive Sheaves. 8) Figure 3-4 Verify that diagonal 1 is equal to diagonal 2. This ensures the system is square. P.S. Length Figure 3-3 99.00 105.00 Diagonal 1 Diagonal 2 99.00 105.00 D.S. Length Figure 3-4 10
Step 8a Install Tarp on Trailer 1) Figure 8-1 Space bow approximately 24" apart. 24.00 24.00 2) Unfold Tarp and stretch across top of bows with the tail in the rear. Figure 8-1 3) Figure 8-2 Line up bows with flaps underneath side of tarp and Bow Ends with grommet in tarp. 4) Figure 8-3. Insert zip tie through hole in flap and wrap around Bow. Trim excess off of zip tie. Zip Tie through hole around Bow Zip Tie through hole around Bow Flaps underneath Figure 8-2 Figure 8-3 5) Figure 8-4. Line up bow with grommets in tarp. Secure tarp to bow ends with drop plate via #14 X 1-1/4 Truss PH screw thru plate on each side. Make sure tarp cable is secured. Grommet in Tarp underneath Plate #14 X 1-1/4 Truss PH screw 1/4-20 Nut 1/4 Flat Washer 6) Figure 8-5. Pull tarp sections between bows UP to form uniform pleats. Figure 8-4 Tarp Cable Drop Plate #14 X 1-1/4 Truss PH screw 7) Figure 8-6. Train pleats by crimping tarp edge cable between each bow and at the grommet. Figure 8-5 Figure 8-6 11
Step 8b Install Tarp on Ground (Optional) 1) Figure 8-7. Unroll tarp upside down (flaps for bows up) on clean, flat floor surface. 2) Figure 8-8. Align bows with flaps on tarp. Power bow is near the tail. Figure 8-7 3) Figure 8-8. Line up bows with flaps underneath and Bow Ends with grommet in tarp. 4) Figure 8-9 Insert zip tie through hole in flap and wrap around Bow. Trim excess off of zip tie. Zip Tie through hole around Bow Zip Tie through hole around Bow Flaps underneath Figure 8-8 Figure 8-9 5) Figure 8-10. Line up bow with grommets in tarp. Secure tarp to bow ends with drop plate via #14 X 1-1/4 Truss PH screw thru plate on each side. Make sure tarp cable is secured. Grommet in Tarp underneath Plate #14 X 1-1/4 Truss PH screw 1/4-20 Nut 1/4 Flat Washer Figure 8-10 6) Figure 8-11, 8-12, & 8-13. Slide bows together and insert a 5 length of 1/4" cable through accessory hole of each single Bow End. NOTE: DO NOT include power bow in stack up Figure 8-12. NOTE: DO NOT insert cable into drive cable hole Figure 8-13. Tarp Cable Drop Plate #14 X 1-1/4 Truss PH screw Figure 8-11 Figure 8-12 Figure 8-13 12
Step 8b (cont.) 7) Figure 8-14. Place a clamp on one end of each cable. 8) Figure 8-15. Compress bow stack and lock in place with second cable clamp. 9) Figure 8-16. Turn tarp assembly right side up. Figure 8-14 Figure 8-15 Figure 8-16 10) Figure 8-17. Pull tarp sections between bows UP to form uniform pleats. 11) Figure 8-18. Train pleats by crimping tarp edge cable between each bow. Figure 8-17 Figure 8-18 12) Figure 8-19. Flip front tarp flap on top of tarp assembly. 13) Figure 8-20. Set power bow assembly on top of tarp assembly. 14) Figure 8-21. Place tarp assembly on top rails approximately 36" from rear of trailer. 36" Figure 8-19 Figure 8-20 Figure 8-21 13
Step 8c Set the Power Bow Location and Attach Tarp to Power Bow 1) Figure 8-22. Run the system back until the power bow is 1" - 2" in front of the rear idler or the adjustment bolt on the rear idler. 1" - 2" 1" - 2" 1" - 2" Power Bow stops at Adjustment Bolt Power Bow Extension stops at Rear Idler Figure 8-22 Power Bow stops at Rear Idler Tarp Cable 2) Figure 8-23. Pull tarp over edge of power bow and place tarp cable between studs. Holes will need to be punched in tarp to go top studs to go through. 3) Place tarp bracket over studs and secure with 5/16-18 nylon hex nuts. 2 places on both sides of the unit. Grommet in Tarp underneath Plate Drop Plate #14 X 1-1/4 Truss PH screw Figure 8-23 Step 8d Attach Tarp to Wind Deflector 1) Figure 8-24. Pull tarp tight across wind deflector (A). Note: It is important to pull tarp as tight as possible to minimize the travel of the power bow when closing the system. 2) Figure 8-24 Place tarp strap across mounting ledge and insert self tapping screws (B). Continue to pull the tarp tight at each screw location. B B B B A A A 3) Run tarp towards the rear to stretch the tarp. If the power bow hits the rear idler run the power bow forward approximately 1" 4) Remove screws from strap and pull tarp tight and replace strap and screws. 5) Repeat this steps until power bow stops before hitting rear idler. Figure 8-24 14
Step 8d (cont.) 6) Figure 8-25. Pull tarp over edge of tension bracket and 7) Figure 8-25. Place tarp bracket over studs and secure with 5/16-18 nylon hex nuts. 2 places on both sides of the unit. #14 x 1-1/4 Truss Head 1/4" Flat Washer Drop Plate Trim Tarp #14 x 1-1/4 Truss Head C Figure 8-25 8) Figure 8-26. Trim excess tarp away from wind deflector (C). Figure 8-26 9) Figure 8-25. Cut tarp cable (using cut off disk) a few inches in front of the tarp bracket. Insert screw and washer into the side of the wind deflector and wrap the tarp cable around it and tighten. 10) Repeat for both sides of trailer. 11) Slowly, using drive unit, run the system forward and backwards to test the system. Figure 8-27 15
Call 1-800-535-9545 www.aeroindustries.com INDIANAPOLIS, IN Indianapolis, IN 46241 800-535-9545 FAX: 317-244-1311 OMAHA, NE Omaha, NE 68137 800-535-9545 FAX: 402-895-6129 KENT, OH Kent, OH 44240 888-237-2262 FAX: 330-626-3277 2014 Aero Industries, Inc. PRODUCT US: 4854630, 6139085, 6481779, 6582007, other patents pending Canada: 2455928, 2574047 Aero Industries, Inc. 0930-111302 10/05/16 Rev A