AeroForce S2S. Installation Instructions. AeroForce S2S For End Dumps

Transcription

1 AeroForce SS For End Dumps Serving the Truck & Trailer Industry Since 9 AeroForce SS Attention Dealers: Please give this manual to the customer when product is delivered. Call Indianapolis, IN Omaha, NE Kent, OH

2 AeroForce SS For Dumps Installation Directory Item Step Page Safety Information Warranty Information and Tools Required Front Caps Fabric Front Cap: Mark Top Rail for Bow Placement Fabric Front Cap: Install Double Bow Bracket or Heavy Duty Bows Fabric Front Cap: Install Aluminum Trough Aluminum Front Cap: Install Square Nose Aluminum Front Cap: Install Shaped to Nose a b c d e Rear Caps Fabric Rear Cap: Install Double Bow Bracket or Heavy Duty Bows Fabric Rear Cap: Install Aluminum Trough Aluminum Rear Cap: Install Mounted to Tailgate Aluminum Rear Cap: Install with Fabric Tail a b c d Bows Marking Bow Location Installing Aluminum Bows Installing Adjustable Steel Bows Installing Heavy Duty Bows Installing Flex Bows & Double Flex Bows a b c d e Installing Roll Stops and Secure Anchor Pipe 0 Install Latch Plate 5 Roll Pipe and Anchor Pipe " Aluminum Roll Pipe Steel Roll Pipe " Aluminum Roll Pipe Assemble Anchor Pipe 6a 6b 6c 6d, 6e 5-6 Mounting Arm Mounts (Front) 7a, 7b 7-8 Mounting Arm Mounts (Rear) 8a, 8b 9-0 Mounting Front Arm 9a, 9b Mounting Rear Arm 0a, 0b, 0c - Roll Pipe Hookup a, b Roll Pipe Rear Hookup a, b 5-6 Rear Tensioner c 7 Wiring Semi-trailer Truck Wiring Semi-trailer Wiring Optional Remote Wiring Alternate Remote Wiring a b c d How to Operate AeroForce SS Safety Messages Related to the Operation of AeroForce SS How to Maintain AeroForce SS Safety Messages Related to the Maintenance of AeroForce SS

3 AeroForce SS Important Safety Information Explanation of Signal Words WARNING: Indicates a hazardous situation which, if not avoided could result in death or serious injury. CAUTION: Indicates a hazardous situation which, if not avoided could result in minor or moderate injury. General Safety Messages WARNING: Read this entire manual and all safety messages before installing and operating this product. WARNING: Always wear safety glasses during installation and operation. CAUTION: Keep all clothing clear of moving parts. CAUTION: Keep everyone clear of the area. Safety Messages related to the Installation of AeroForce SS CAUTION: Use caution lifting heavy components. Use more than one person and/or proper equipment to handle components. CAUTION: Use caution while installing the swing arms, springs are under spring tension. Arms may rotate unexpectedly. WARNING: Use OHSA approved ladders or scaffolding to work above ground level. Be sure that your working platform is secure as you work on the truck. WARNING: Properly fasten all components. If not properly secured components may come loose. IMPORTANT: Contains information critical to installation, operation, or warranty policy. NOTICE: Is used to address practices not related to physical injury. Risk of product or vehicle being damaged. NOTE: Contains information critical to the installation or operation of this product. IMPORTANT: This tarp system must have arched bows to support the tarp fabric when closed. As such, When not in use, the tarp should be fully opened to prevent moisture from collecting on the tarp surface. Failure to open tarp could cause damage to the tarp system and will not be covered by warranty.

4 AeroForce SS This manual explains how to install and maintain an AeroForce SS Roll Tarp system. Aero Warranty Aero Products come with a one year warranty on all parts. It's another example of our ongoing commitment to customer satisfaction and quality. Customer: If you have any concerns or questions prior to the installation of this product, please call our Customer Service at Tools Required for Installation Marker or Felt Pen Drill Bits: 9/", /", /" Tape Measure Sockets: 5/6", 7/6", 9/6", /", ", -/8" Black Electrical Tape Open End or Box Wrenches: 5/6", 7/6", 9/6", /", ", -/8" Awl Phillips: # Hammer Electric or Air Drill Saw Welder Allen Wrench Set

5 AeroForce SS Step a Fabric Front Cap: Mark Top Rail for Bow Placement ) Figures 5- & 5-. Mark the top rail where flat on side of trailer starts. Also mark 0" from there for heavy duty bows. The dimension of the Radius, Diagonal, or Offset. Flat on side of trailer Flat on side of trailer Flat on side of trailer O R D D.S. D.S. D.S. Front Front Front Offset Corner Diagonal Corner Radius Corner Figure 5-0" R, D or O D.S. Flat on side of trailer Front 0" Heavy Duty Bows R, D or O D.S. Flat on side of trailer Front R, D or O Double Bow Bracket 9-/" Flat on side of trailer Aluminum Trough Figure 5-5

6 AeroForce SS Step b Fabric Front Cap: Install Double Bow Bracket or Heavy Duty Bows Index Description Fabric Front Cap Heavy Duty Bracket A Double Bow or Double Bow W/Insert Bows /8 x Type F HWH 5 5/6 x -/ Type F Torx 6 Aluminum Flat Bar /8" x " 7 Bow Tie Bar Install Heavy Duty Bracket Figure 6-. Position heavy duty brackets centered on marks on top rail. Attach with /8 x type F HWH bolts. 0" R, D or O 5 ft Install Double Bow Bracket Insert Double Bow Bracket Double Bow Bracket No Insert W/Insert ) Figure 6-. Clamp first pocket of 0" double bow bracket centered on mark on top rail. R, D or O ) Figure 6-. Position bracket as shown to reduce tarp wear. Heavy Duty Bracket Figure 6-0" R, D or O Note: Put the bolts in the center of the slots in case pocket needs to be adjusted. a) Figure 6-. Attach with /8 x type F HWH bolts. b) Figure 6-. Attach with /8 x -/ carriage bolts. Double Bow Bracket on Passenger Side Double Bow Bracket W/Insert on Drive Side Install Double Bow Bracket to Sideboards Hardware to Mount to Sideboards Index Description Figure 6-7 5/6 X -/ CARRIAGE BOLT 6 8 5/6 FLAT WASHER 6 9 5/6 LOCK WASHER 6 5/6 HEX NUT 6 0 Figure 6-6

7 AeroForce SS Bow Through Pocket Step b (cont.) Fabric Front Cap 5) Figure 7-. Feed bow through pocket of fabric cap and install on trailer. On adjustable bows remove bolt and pin. Orient the bow so the end with the removable pin is on the passenger side. 6) Install heavy duty bows per Step d. Center Bolts Figure 7-6a) Figure 7-. Adjustable bows are tied together with the Bow Tie Bracket, flat washers, lock washers, and bolts removed in earlier step. 7) Figure 7-. Pull cap tight over top rail. 8) Figure 7-. Drill holes evenly spaced through aluminum flat bar and attach with 5/6 x - / Type F Torx. Double Bow Bracket W/Insert on Drive Side Adjustable Pin Double Bow Bracket on Passenger Side Figure 7- IMPORTANT: If the cap is not pulled tight, a gap with the roll tarp will allow wind to get underneath and cause wear. Fabric Cap No Gap Roll Tarp Fabric Cap Gap Roll Tarp Double Bow Figure 7- Pull cap to tighten 5/6 x -/ Type F Torx Aluminum Flat Bar Figure 7-7

8 AeroForce SS Step c Fabric Front Cap: Install Aluminum Trough Index Description Index Description Fabric Front Cap 5 Bolt Carr /8-6x-/ Angle Bracket Trough 6 Nut Hex /8-6 Trough Extrusion Rolled 7 Washer Flat /8" /8 x Type F HWH 8 Aluminum Flat Bar /8" x " ) Figure 8-. Verify trailer width subtract " for trough width, see table, find length base on trailer width and rise, cut to size. Ft Length Rise ) Figures 8- & 8-. Position Angle Bracket Trough with the slotted holes against the trailer and clamp to trough. Trough Width ) Figure 8-. Position trough /" from outside edge of trailer on both sides and clamp in place. Figure 8- NOTE: The trough width maybe wider than the trailer, push the trough so it is /" from the outside of the trailer and clamp in place. Check the rise to verify it is correct and make any necessary adjustments. Trailer Width 96" Trough Width 95" ) Figure 8-. Drill two /" diameter holes through trough and bracket. 96" 95" 0" 0" 0-5/6" 0" 0" 0-5/8" Length 96" 97-/" Rise 6" 0" 6" 0" 5) Figure 8-. Attach with /8-6 x -/" carriage bolt, /8 flat washer, and /8-6 nylon hex nut. 6) Figure 8-5. Grind end of trough at 0 angle, free from burrs, to reduce wear on tarp. NOTE: Bracket can be welded to Aluminum Trailer. 0 / Figure 8- Figure 8- Figure 8- Figure 8-5 8

9 AeroForce SS Step c (cont.) 7) Figure 9-. Position aluminum trough at the R, D, or O plus any trough offset specified on order. 9.5" 8) Figure 9-. Drill pilot holes for /8" x " type F and secure to trailer. R, D or O Plus Trough Offset Figure 9-9) Figure 9-. Feed aluminum flat bar through bottom of fabric cap. 0) Figure 9-. Feed fabric cap through front keder of aluminum trough. ) Figure 9-. Pull cap tight over top rail. ) Figure 9-. Drill holes evenly spaced through aluminum flat bar and attach with 5/6 x - / Type F Torx. Fabric Cap Front Keder Aluminum Trough Aluminum Trough Pull cap to tighten Figure 9- Figure 9-5/6 x -/ Type F Torx Aluminum Flat Bar Figure 9-9

10 AeroForce SS Step d Aluminum Front Cap: Install Square Nose Index Description Front Cap Square Aluminum /8 x Type F HWH ) Figure 0-. Measure and make any cut-outs and place cap on trailer. ) Attach with /8 x Type F HWH Bolts through trough into top rail. Step e Aluminum Front Cap: Install Shaped to Nose Index Description Front Cap Aluminum Aluminum Strip /8 x /8 x Type F HWH ) Place cap on front of trailer, center and push lip up against the trailer. ) Figure 0-. Trace the corner shape of nose onto front cap and cut-out shape Trace Shape Radius Corner Trace Shape Diagonal Corner Figure 0- Trace Shape Offset Corner Figure 0- ) Figure 0-. Attach with /8 x Type F HWH Bolts through trough into top rail. ) Figure 0-. Shape the aluminum strip around the corner of the trailer, mark and cut to length for both sides. 5) Figure 0-. Weld both pieces to the front cap. Weld Shape Strip Weld Shape Strip Figure 0- Figure 0-0

11 AeroForce SS Step a Fabric Rear Cap: Install Double Bow Bracket or Heavy Duty Bows Index Description Install Heavy Duty Bracket Fabric Rear Cap Heavy Duty Bracket Double Bow or Double Bow W/Insert Bows /8 x Type F HWH 5 Bow Tie Bar A Figure -. Position heavy duty brackets centered on marks on top rail. Attach with /8 x type F HWH bolts. 0" 6 0" Install Double Bow Bracket Double Bow Bracket No Insert Insert Double Bow Bracket W/Insert ) Figure -. Measure and mark 0" from the outside of the tailgate and 0" towards the rear from the previous mark. Heavy Duty Bracket Figure - ) Figure -. Clamp first pocket of double bow bracket centered on mark on top rail. 0" 0" ) Figure -. Position bracket and bow as shown to reduce tarp wear. Note: Put the bolts in the center of the slots in case pocket needs to be adjusted. a) Figure -. Attach with /8 x type F HWH bolts. b) Figure -. Attach with /8 x -/ carriage bolts. Note: There may be up to different widths of aluminum bows, make sure you have the right one. Double Bow Bracket W/Insert on Drive Side Double Bow Bracket on Passenger Side Install Double Bow Bracket to Sideboards Hardware to Mount to Sideboards Index Description Figure - 7 5/6 X -/ CARRIAGE BOLT 6 8 5/6 FLAT WASHER 6 9 5/6 LOCK WASHER 6 5/6 HEX NUT 6 0 Figure -

12 AeroForce SS Step a (cont.) 5) Figure -. Feed bow through pocket of fabric cap and install on trailer. On Bow Through adjustable bows remove bolt and pin. Pocket Orient the bow so the end with the removable pin is on the passenger side. Fabric Rear Cap 6a) Install heavy duty bows per Step d. 6b) Figure -. Adjustable bows are tied together with the Bow Tie Bracket, flat washers, lock washers, and bolts removed in earlier step. Tail Center Bolts Figure - Note: Driving with the tarp open may cause air to lift the rear cap and the bow coming out of the pocket. Placing a pin through the bow and pocket will prevent this from happening. 7) Figure -. Drill /6" hole through the bow and pocket towards the front on both sides. Insert /6" hair pin in drilled holes. Double Bow Bracket 8) Figure -. Pull cap tight when W/Insert on Drive Side securing with Latch Plate or Roll Stop. Adjustable Pin Double Bow Bracket on Passenger Side Figure - Ø/6 Through Pocket and Bow Fabric Cap No Gap Roll Tarp Fabric Cap Gap Roll Tarp /6" Hair Pin Figure - Figure -

13 AeroForce SS Step b Fabric Rear Cap: Install Aluminum Trough Index Description Index Description Fabric Cap 6 Nut Hex /8-6 Angle Bracket Trough 7 Washer Flat /8" Trough Extrusion Rolled 8 Aluminum Flat Bar /8" x " /8 x Type F HWH 9 Pin Hair /6x.5" 5 Bolt Carr /8-6x-/ ) Figure -. Verify trailer width subtract " for trough width, see table, find length base on trailer width and rise, cut to size. ) Figures - & -. Position Angle Bracket Trough with the slotted holes against the trailer and clamp to trough. ) Figure -. Position trough /" from outside edge of trailer on both sides and clamp in place. Note: The trough width maybe wider than the trailer, push the trough so it is /" from the outside of the trailer and clamp in place. Check the rise to verify it is correct and make any necessary adjustments. ) Figure -. Drill two /" diameter holes through trough and bracket. Ft Length Rise Trough Width Figure - Trailer Width 96" Trough Width 95" Length 96" Rise 6" 96" 95" 0" 0" 0-5/6" 97-/" 0" 0" 0-5/8" 0" 6" 0" 5) Figure -. Attach with /8-6 x -/" carriage bolt, /8 flat washer, and /8-6 nylon hex nut. 6) Figure -5. Grind end of trough at 00 angle, free from burrs, to reduce wear on tarp. NOTE: Bracket can be welded to Aluminum Trailer. Drill /" holes. Secure with /8-6 x -/" carriage bolt Grind to a 00 angle 0 / Figure - Figure - Figure - Figure -5

14 AeroForce SS Step b (cont.) 7) Figure -. Position the front of the aluminum trough at 0" from the outside of the tailgate. 8) Figure -. Drill pilot holes for /8" x " type F and secure to trailer. NOTE: Bracket can be welded to Aluminum Trailer. 0" 9.5" /8 x type F Figure - 9) Figure -. Feed fabric cap through back keder of aluminum trough. 0) Figure -. Pull cap tight when securing with Latch Plate or Roll Stop. Back Keder Drop of Cap Tail Latch Plate Pull cap to tighten Figure - Figure -

15 AeroForce SS Step c Aluminum Rear Cap: Install Mounted to Tailgate Index Description Rear Cap Aluminum Tailgate /8 x Type F HWH Aluminum Cap ) Figure 5-. Position aluminum rear cap centered on inside of tailgate with the bottom of the trough even with the side walls. ) Drill pilot holes and secure with /8 x Type F HWH bolts. /8 x Type F HWH Figure 5- Step d Aluminum Rear Cap: Install with Fabric Tail Index Description Aluminum Cap Rear Cap Aluminum with Tail Fabric Rear Tail for Aluminum Cap /8 x Type F HWH /8 x Type F HWH ) Figure 5-. Position aluminum rear cap on top rail centered on width, locate the front edge of cap 0" from outside of tailgate. 0" ) Drill pilot holes and secure with /8 x Type F HWH bolts. Figure 5- ) Figure 5-. Insert welt on tail into keder on back of cap and center on width. Use light oil to slide welt in keder. Aluminum Cap Welt Keder Fabric Tail Figure 5-5

16 AeroForce SS Step a Marking Bow Location ) Mark top rail according to what caps are on the trailer. IMPORTANT: DO NOT exceed 8" spacing for bow centers. This will void the warranty. IMPORTANT: This tarp system must have arched bows to support the tarp fabric when closed. As such, When not in use, the tarp should be fully opened to prevent moisture from collecting on the tarp surface. Failure to open tarp could cause damage to the tarp system and will not be covered by warranty. Last bow Tailgate Aluminum Front Cap Fabric Rear Tail First bow after cap Equally spaced not to exceed 8" First bow before cap Equally spaced not to exceed 8" 0" First bow after cap Aluminum Front Cap Aluminum Rear Cap Mounted to Tailgate 8" Equally spaced not to exceed 8" Front First bow Fabric Front Flap Fabric Rear Tail Last bow Last bow 8" Tailgate Front R, D or O 8" if square Fabric Front Cap Fabric Rear Cap 0" 8" 8" Front First bow after cap 8" First bow after cap First bow before cap 8" Tailgate Equally spaced not to exceed 8" Tailgate 8" Fabric Front Cap Fabric Rear Tail Equally spaced not to exceed 8" Front Front First bow after cap 0" Tailgate 8" Equally spaced not to exceed 8" First bow before cap Aluminum Front Cap Aluminum Rear Cap with Tail 0" 6

17 AeroForce SS Mark on top rail Step b Installing Aluminum Bows ) Figure 7-. Align aluminum pocket with marked bow location and flush with top of rail. WELD a) Weld down each side of pocket. /8 x Type F HWH BOLT Figure 7- b) Drill a pilot hole and attach with /8 x type F HWH bolts. ) Figure 7-. Insert bow into pockets. Figure 7- Step c Installing Adjustable Steel Bows ) Figures 7- & 7-. Align steel pocket with marked bow location and adjust height so bend in bow is even with the top rail. a) Figure 7-. Drill a pilot hole and attach with /8 x type F HWH bolts. b) Figure 7-5. Drill a pilot hole and attach with /8 x type F HWH bolts. Bracket can be positioned high or low Figure 7- ) Figure 7-6. Loosen set screw on bow. Insert bow into one pocket. Adjust width and then insert into the other pocket. Tighten the set screw. Mark on top rail Install Bow Bracket to Sideboards Hardware to Mount to Sideboards Index Description 5/6 X -/ CARRIAGE BOLT 8 5/6 FLAT WASHER 8 5/6 LOCK WASHER 8 5/6 HEX NUT 8 /8 x Type F HWH Figure 7- Figure 7-5 Set Screw Figure 7-6 7

18 AeroForce SS Step d Installing Heavy Duty Bows ) Figures 8- & 8-. Align bracket with marked bow location and place on top of rail. ) Figure 8-. Drill a pilot hole and attach with /8 x type F HWH bolts. Repeat for opposite side. ) Figure 8-. Attach swivel bracket assembly to base with headless pin and cotter pins. ) On opposite side attach heavy duty bow assembly with headless pin and cotter pin. Mark on top rail Cotter Pins Headless Pin Figure 8- /8 x Type F HWH Swivel Bracket Assembly Figure 8-5) Figure 8-. Mark heavy duty bow assembly, disassemble, and cut to length. 6) Figure 8-. Reassemble with swivel bracket assembly inserted into the heavy duty bow assembly. Mark and cut bow Figure 8- Figure 8-8

19 AeroForce SS Step e Installing Flex Bows & Double Flex Bows BOLT a) Figure 9-. Drill x bolt clearance holes in bow pocket flanges for /8 bolts. Holes should be /" min. from flange edges. Align pocket with marked bow location and flush with top rail. Drill pilot holes and attach with /8 x type F HWH bolts. WELD b) Figures 9- & 9-. Align pocket with marked bow location and flush with top of rail. Weld all around pocket. Bolt Mark on top rail Figure 9-. For sideboard installations weld or bolt the pocket to a plate. Mark on top rail Support plate /8 x Type F HWH Figure 9- Weld Mark on top rail Weld plate on top rail Figure 9- Figure 9- IMPORTANT: The ends of the bow must be cut to the proper angle or the warranty is void. The flex bow has a pre-set arch or spline, make sure the arch is up when cutting the ends. ) Figure 9-. Cut both ends of the flex bow at angle and " longer than the inside width of the trailer. ) Figure 9-5. Insert bow into pockets. 5-0 Inside Trailer Width + for 0 Rise + for Rise 5-0 Figure 9-5 Figure 9-9

20 AeroForce SS 5-9 Step 5-9 Installing Roll Stops and Secure Anchor Pipe ) Figures 0- & 0-. Locate first roll stop bracket 5"-9" from the first bow and " down from top rail. Note: Tarp & end of anchor pipe should be " from center of same bow ) Figures 0- & 0-. Drill a pilot hole and attach with /8 x type F HWH bolts. ) Locate last roll stop bracket 5"-9" from end of anchor pipe or as close as possible and " down from top rail. ) Evenly space roll stop brackets along top rail with maximum of 96" apart. Sideboards (Optional) Note: Anchor pipe can be mounted in the roll stop or to the top rail. Mounting the anchor pipe to the top rail allows the tarp to cover the gap at the bottom of the sideboard, install tarp and secure anchor pipe before installing roll stops. ) Figure 0-. OPTIONAL Attach tarp and anchor pipe to top rail with clamps # screws. Figure 0- Top Rail " ) Figures 0- & 0-. Locate roll stops the same distance from the bows as in Step. and " from top of sideboard. ) Figures 0- & 0-. For sideboards. Drill a pilot hole and attach with /8 x -/ carriage bolts. ) Figure 0-. Attach aluminum flat at top of sideboard for the full length of the tarp. Figure 0- Install Anchor Pipe to Top Rail & Roll Stops to Sideboards Install Anchor Pipe & Roll Stops to Sideboards Hardware to Mount to Sideboards Index Description Figure 0-5/6 X -/ CARRIAGE BOLT 5/6 FLAT WASHER 5/6 LOCK WASHER 5/6 HEX NUT 5 /8" x " x ' FLAT ALUMINUM 6 SCREW # X HWH AB ZINC 7 CLAMP, ANCHOR PIPE 8 /8 X TYPE F HWH BOLT Figure 0-0

21 AeroForce SS Step 5 Install Latch Plate Note: Check to ensure the roll tube will have a clear path past the tailgate. Shim latch plate if needed. Latch Plate Note: Latch plate can be mounted to the top rail or to the sideboards. Mounting the latch plate to the top rail with sideboards allows the tarp to cover the gap at the bottom of the sideboard. Front Edge of Tarp ) Figures - & -. Locate the latch plate " forward of the front edge of the tarp and "-5" below the top rail or as high as possible. " Note: Front edge of latch plate can be cut at a 50 angle when beyond the flat of the side wall. Figure - ) Figure -. Drill a pilot hole "-" in from each end and every " in each section. Note: First hole may need to be farther back where the flat side wall starts. a) Figure -. Attach with /8 x type F HWH bolts. b) Figure -. Optional mounting to sideboards: Attach with /8 x -/ carriage bolts. Note: Rear edge of latch plate may need to be cut at a 50 angle as to not interfere with the swing gate. ) Cut the last section so it goes back at least " past the end of the tarp. Top Rail Top Rail " to 5" Maximum - " " /8" x " Latch Plate Latch Plate " (Typical) Figure - - " Figure - Install Latch Plate to Sideboards Hardware to Mount to Sideboards Index Description 5/6 X -/ CARRIAGE BOLT 8 5/6 FLAT WASHER 8 5/6 LOCK WASHER 8 5/6 HEX NUT 8 Figure -

22 AeroForce SS Step 6a " Aluminum Roll Pipe ) Figure -. Drill () 5/6 holes through both pipes. The two holes farthest apart are to be drilled 90 degrees with regards to the closest holes. Assemble each splice section using supplied hardware shown in Figure -. 05/6 THRU HOLES ) Figure -. At one end, drill () /8 holes through the " pipe. The two holes will be " apart with one hole " from the end of the pipe. The two holes will be 90 degrees from each other. 8 ) Figure -. Assemble the roll pipe and adapter using supplied hardware shown in Figure -. Figure - 0/8 THRU HOLES Figure - 8 Index Description ALUM " SCH80 PIPE SPLICE SEGMENT, ROLL PIPE BOLT BHSCS /-0 X / WELD NUT /-0 TAB BASE 5 SHAFT, ADAPTER FOR " ALUM. ROLL PIPE 6 5/6-8 UNC X - BOLT HHCS 7 5/6 - USS FLAT WASHER 8 5/6-8 NYLON LOCK NUT Figure -

23 AeroForce SS Step 6b Steel Roll Pipe ) Figure -. Slide each pipe together. This also includes the pipe with adapter already welded on it. ) Figure -. Weld each spliced section. Weld Figure - Figure - Index Description 5' PIPE, ADAPTER ASSY STEEL ROLL PIPE

24 AeroForce SS Step 6c " Aluminum Roll Tape ) Figure -. Using the center lines in the valleys of the roll pipe, drill three /" holes " back from the end at 0 degrees from each other and make sure they line up with the holes in the drive adapter assembly. Index Description " ROLL PIPE DRIVE ADAPTER ASSEMBLY " ROLL PIPE SPLICE SCREW / X / PHPH S/T Figure - Note: If you are using the Internal Tensioner, the rear section of the roll pipe needs to be at least 7' long to allow the Internal Tensioner to fit inside of the roll pipe. Note: If you are splicing two sections together, the front section needs to be at least ' long. ) Figure -. If you are using just one roll pipe then jump to the next step. Using the center lines in the valleys of the roll pipe, drill three /" holes " back from the end at 0 degrees from each other and make sure they line up with the holes in the roll pipe splice. You will need to repeat the step for both roll pipes and for each splice you are doing. Figure -

25 AeroForce SS Step 6d Assemble Anchor Pipe ) Figures 5- & 5-. Insert swaged end of the tube adapter assembly into the front end of the roll pipe and weld in place. Swaged End ) Figure 5-. Cut the anchor pipe flush with the ends of the pocket on the tarp. Figure 5- ) Place rubber cups on ends of anchor pipe. ) Figure 5-. Slide the anchor pipe into the tarp pocket and secure with # x PPH self drilling screw at each end. 5) Figure 5-. Slide the roll pipe into the other pocket and leave sticking out at both ends of the tarp. Weld Figure 5- Anchor Pipe Strap Roll Pipe Rear Strap Figure 5-5

26 AeroForce SS Step 6e Assemble Anchor Pipe ) Figures 6- & 6-. Insert swaged end of the tube adapter assembly into the front end of the roll pipe and weld in place. ) Figure 6-. Cut the anchor pipe flush with the ends of the pocket on the tarp. ) Place rubber cups on ends of anchor pipe. Figure 6- ) Figure 6-. Slide the anchor pipe into the tarp pocket and secure with # x PPH self drilling screw at each end. 5) Figure 6-. Slide the tarp into the large groove in the roll pipe. Figure 6- Figure 6- Anchor Pipe Tarp Roll Pipe Figure 6-6

27 AeroForce SS Step 7a Mounting Arm Mounts (Front Standard Roll) Note: Figure 7-. Center of the pivot needs to be in the center of the trailer. ) Figure 7-. Drill four /8" holes using the mounting bracket as a template for the hole locations. ) Figure 7-. Use supplied hardware to mount the mounting bracket to the trailer. Figure 7- Figure 7- Inside the trailer. Index Outside the trailer. Note: Mounting Brackets are supplied with standard pivot mounting hole locations at /8" dia. through. Standard pivot mounting holes must be drilled out to 7/8" dia. for proper fastener fit. If alternate hole locations are required, holes must be marked and drilled through at 7/8" dia. Part Number Description BRACKET, ARM MOUNTING /6-8 UNC - - BOLT HHCS /6-8 NYLON LOCK NUT /6 - USS FLAT WASHER 8 Figure 7-7

28 AeroForce SS Step 7b Mounting Arm Mounts (Front Reverse Roll) W Note: Figure 8-. Center of the pivot needs to be in the center of the trailer. W/ ) Figure 8-. Drill eight /8" holes using the mounting bracket as a template for the hole locations. 9 ) Figure 8-. Use supplied hardware to mount the mounting bracket to the trailer. 5 / 0 / Figure 8- Drill eight /8" holes using the Mounting Bracket as a template for the hole locations. Figure 8- Note: Mounting Brackets are supplied with standard pivot mounting hole locations at /8" dia. through. Standard pivot mounting holes must be drilled out to 7/8" dia. for proper fastener fit. If alternate hole locations are required, holes must be marked and drilled through at 7/8" dia. Inside the trailer. Index Outside the trailer. Part Number Description BRACKET, PIVOT MOUNTING RR /6-8 UNC - - BOLT HHCS /6-8 NYLON LOCK NUT /6 - USS FLAT WASHER 6 Figure 8-8

29 AeroForce SS Step 8a Mounting Arm Mounts (Rear) Note: Figure 9-. Center of the pivot needs to be in the center of the trailer. ) Figure 9-. Drill four /8" holes using the mounting bracket as a template for the hole locations. ) Figure 9-. Use supplied hardware to mount the mounting bracket to the trailer. Figure 9- Figure 9- Note: Mounting Brackets are supplied with standard pivot mounting hole locations at /8" dia. through. Standard pivot mounting holes must be drilled out to 7/8" dia. for proper fastener fit. If alternate hole locations are required, holes must be marked and drilled through at 7/8" dia. Inside the trailer. Index Outside the trailer. Part Number Description BRACKET, ARM MOUNTING /6-8 UNC - - BOLT HHCS /6-8 NYLON LOCK NUT /6 - USS FLAT WASHER 8 Figure 9-9

30 AeroForce SS 5 Step 8b Mounting Arm Mounts (ForceLink with Coal Door) ) Figure 0-. Assemble the rear arm mounting bracket per the assembly drawing. Index Description HOUSING MOUNTING BRACKET / - USS FLAT WASHER 8 /- NYLON LOCK NUT PLATE, REAR COAL DOOR 5 /- UNC BOLT HHCS Note: Mounting Brackets are supplied with standard pivot mounting hole locations at /8" dia. through. Standard pivot mounting holes must be drilled out to 7/8" dia. for proper fastener fit. If alternate hole locations are required, holes must be marked and drilled through at 7/8" dia. ) Figure 0-. Center the bracket in the center of the rear door, making sure the bracket is 9" down from the top of the bow rise. ) Using the top and bottom holes on the mounting bracket as a guide, drill clearance holes for a /" bolt. Figure ) Mount the bracket to the rear door using the supplied () /-8 x " bolts, (8) /" washers and () /-8 locking nuts. Figure 0-0

31 AeroForce SS Step 9a Mounting Front Arm Standard Roll ) Figure -. Using the supplied hardware, mount the front arm assembly to the mounting bracket located on the front of the trailer. Index Description FRONT ARM ASSY W/MOTOR /-0 UNC BOLT HHCS / - SPLIT LOCK WASHER / - USS FLAT WASHER Note: Mounting Brackets are supplied with standard pivot mounting hole locations at /8" dia. through. Standard pivot mounting holes must be drilled out to 7/8" dia. for proper fastener fit. If alternate hole locations are required, holes must be marked and drilled through at 7/8" dia. Figure - Step 9b Mounting Front Arm Reverse Roll ) Figure -. Using the supplied hardware, mount the front arm assembly to the mounting bracket located on the rear of the trailer. Note: The front assembly is rotated 80 degrees around. The motor assembly will be on the inside between the arm assembly and the front of the trailer. Make sure there are no obstacles within the path of the front arm assembly. Index Description FRONT ARM ASSY W/MOTOR /-0 UNC BOLT HHCS / - SPLIT LOCK WASHER / - USS FLAT WASHER Figure -

32 AeroForce SS Step 0a Mounting Rear Arm Standard Roll ) Figure -. Using the supplied hardware, mount the rear arm assembly to the mounting bracket located on the rear of the trailer. Index Description REAR ARM ASSY W/CHAIN /-0 UNC BOLT HHCS / - SPLIT LOCK WASHER / - USS FLAT WASHER Note: Mounting Brackets are supplied with standard pivot mounting hole locations at /8" dia. through. Standard pivot mounting holes must be drilled out to 7/8" dia. for proper fastener fit. If alternate hole locations are required, holes must be marked and drilled through at 7/8" dia. Figure - Step 0b Mounting Rear Arm Reverse Roll ) Figure -. Using the supplied hardware, mount the rear arm assembly to the mounting bracket located on the rear of the trailer. Note: The rear assembly is rotated 80 degrees around. Index Description REAR ARM ASSY W/CHAIN /-0 UNC BOLT HHCS / - SPLIT LOCK WASHER / - USS FLAT WASHER Figure -

33 AeroForce SS Step 0c Mounting Arms (ForceLink with Coal Door) ) Figure -. Drill two 5/" holes for /" bolts in the top of the bracket so that the pivot pin on the ForceLink is in the center of the trailer. The distance between the holes needs to be 6-/8". L L/ Figure /" Hole.69 Center of Pivot Pin to center of hole. ) Figure -. Using the supplied /" bolts, washers and nuts, install ForceLink onto the mounting bracket. Index Description /-0 UNC BOLT HHCS / - SPLIT LOCK WASHER / - USS FLAT WASHER Figure -

34 AeroForce SS Step a Roll Pipe Hookup Standard Roll (Front - Torque Amplifier) ) Figure -. Insert roll pipe into the gearbox. ) Use the supplied /8-6 UNC X.5" bolt and nut to connect the roll pipe to the output of the gearbox. Index Description /8-6 UNC BOLT HHCS /8-6 NYLON LOCK NUT MOTOR GEARBOX KIT ROLL PIPE Standard Roll View Step b Figure - Roll Pipe Hookup Reverse Roll (Front - Torque Amplifier) ) Figure -. Insert roll pipe into the gearbox. ) Use the supplied /8-6 UNC X.5" bolt and nut to connect the roll pipe to the output of the gearbox. Index Description /8-6 UNC BOLT HHCS /8-6 NYLON LOCK NUT MOTOR GEARBOX KIT ROLL PIPE Reverse Roll View Figure -

35 AeroForce SS Step a " Roll Pipe Rear Hookup ) Figures 5- & 5-. Cut roll pipe down so the chain on the 90 degree casting is inline with the arm. ) Figure 5-. Slide roll pipe over the rear arm pipe bushing. ) Figure 5-. Use the supplied Tek screw to connect the roll pipe to the bushing. Roll Pipe Arm Chain Roll Pipe Figure 5- Figure 5- Index Figure 5- Description ARM, CHAIN ASSY ROLL PIPE TEK SCREWS 5

36 AeroForce SS Step b " Roll Pipe Rear Hookup ) Figures 6- & 6-. Cut down the roll pipe so that when the rear arm adapter is installed the chain is inline with the rear arm. ) Figure 6-. Using the center lines in the valleys of the roll pipe, drill three /" holes " back from the end at 0 degrees from each other and make sure they line up with the holes in the drive adapter assembly. ) Figure 6-. Install the three self-tapping screws to secure the roll pipe to the rear arm. Arm Roll Pipe Chain Roll Pipe Figure 6- Figure 6- Index Description ROLL PIPE FORCELINK (REAR ARM) /-8 SELF-TAPPING SCREWS Figure 6-6

37 AeroForce SS Step c Rear Tensioner Insert Rear Tensioner assembly fully into roll tube, should be an interference fit. ) Pre-drill two holes, 90 degrees opposed, and insert self tapping screws. ) Holes/screws are " from tensioner/roll pipe interface. ) Attach eyebolt inline with tensioner rope/s-hook if possible to limit wear. ) Eyebolt should be approximately " below tensioner rope with sufficient tension on hook/rope (0#). 5) When rear cap on gate is present, attach eyebolt to gate. 6) No rear cap, eyebolt can be attached to rear post or gate (tension rule applies). 7) Insert tensioner s-hook into eyebolt before testing roll-up. Figure 7-7

38 AeroForce SS Step a Semi-trailer Truck Wiring IMPORTANT: Locate Operation/Maintenance Sheet and keep near switch. IMPORTANT: Switch is not rated for outdoor use. ) Find a convenient place on the driver's side under the dashboard to mount the rocker switch with /-0 x " hex bolts ) Mount reversing contactor outside near back of cab with /-0 x " hex bolts. ) Run wire from switch to reversing contactor. Run wire from battery to reversing contactor. Secure all wire with clamps. ) Connect breaker to battery and secure with zip ties. 5) Run wires from reversing contactor to plug, making sure there is enough wire to reach the receptacle. FWD + - POS NEG 6) Place cover on reversing contactor. REV 8

39 AeroForce SS Step b Semi-trailer Wiring ) Mount receptacle in convenient location. Terminal ) Run wire from receptacle to AeroMax. Secure all wire with clamps. Terminal Terminal + - POS NEG Terminal Step c Optional Remote Wiring IMPORTANT: Locate Operation/Maintenance Sheet and keep in a convenient location. IMPORTANT: Remote receiver must be mounted with the wires at the bottom. The optional remote kit replaces the use of the rocker switch. Follow Step a and replace the rocker switch with the remote receiver. ) Mount the remote receiver to the back of the cab with the provided screws. ) Connect remote receiver to reversing DC Contactor. Secure all wire with clamps. Red to +BAT Blue to T Green to T Black to GND 9

40 AeroForce SS Step d Alternate Remote Wiring IMPORTANT: Locate Operation/Maintenance Sheet and keep in a convenient location. Semi-trailer Truck Wiring ) Connect breaker to battery and secure with zip ties. ) Run wire from battery to receptacle. Secure all wire with clamps. + - POS NEG Semi-trailer Wiring ) Mount receptacle in convenient location on trailer. 0

41 AeroForce SS Step d (cont.) ) Mount reversing contactor under the nose of the trail with /-0 x " hex bolts. WARNING: DO NOT place remote receiver in the path of the swing arm, or injury could occur. Mount it on the face of the trailer on the same side as the anchor pipe. IMPORTANT: Remote receiver must be mounted with the wires at the bottom. 5) Mount the remote receiver to the back of the cab with the provided screws. Red to +BAT Green to T Blue to T 6) Connect remote box to reversing DC Contactor. Secure all wire with clamps. Black to GND 7) Connect receptacle to reversing DC contactor. Secure all wire with clamps. Red to +BAT GND + - POS NEG +BAT Black to GND Terminal Terminal 8) Connect reversing DC Contactor to AeroMax. Secure all wire with clamps. IMPORTANT: The reversing DC contactor should be mount under the nose of the trailer NOT near the AeroMax.

42 AeroForce SS How to Operate AeroForce SS NOTICE: NOT releasing the switch when the covered or uncovered position is reached may cause the AeroMax to burn out. Switch Push to uncover unit and release when fully uncovered. Push to cover unit and release when fully covered. Remote Operation To operate the remote, disable the safety lock out by pushing both buttons for seconds. NOTE: After minute of not pushing a button on the remote the safety lock out is activated. Key FOB Receiver Push to cover unit and release when fully uncovered. Uncover Manual Switch Tarp Push to uncover unit and release when fully covered. P555-AER-05 IC: 665A-500R Made in the USA Cover SN Explanation of Signal Words WARNING: Indicates a hazardous situation which, if not avoided could result in death or serious injury. CAUTION: Indicates a hazardous situation which, if not avoided could result in minor or moderate injury. Safety Messages Related to the Operation of AeroForce SS Maintenance recommendations, safety messages, and repair instructions can be found at or call CAUTION: Routinely inspect tarp and swing arms, DO NOT operate if parts are worn or damaged. Worn or damaged parts may come loose. Replace all worn or broken parts IMMEDIATELY. CAUTION: If the arms are damaged or fail to rotate freely under normal operation, DO NOT operate. Secure any damaged parts until repairs can be made. WARNING: The swing arms rotate under extreme spring tension during operation. Make sure no one is in the path of or on the arms. Terminal Terminal

43 AeroForce SS How to Maintain AeroForce SS IMPORTANT: Replace all worn or broken parts immediately. Repairs must ONLY be made after proper instruction. Minimal maintenance is required for the AeroForce SS. Individual usage and operating conditions will determine when to check the AeroForce SS. Aero Industries recommends a weekly inspection of the following items: 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. Lubricate as often as necessary with penetrating oil. DO NOT use an excessive amount of lubricant. Springs: Examine springs for breakage or distortion. Apply a light coat of penetrating oil to tension springs as needed. Fasteners: Make sure that all mounting bolts and screws 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. Explanation of Signal Words WARNING: Indicates a hazardous situation which, if not avoided could result in death or serious injury. CAUTION: Indicates a hazardous situation which, if not avoided could result in minor or moderate injury. Safety Messages Related to the Maintenance of AeroForce SS Maintenance recommendations, safety messages, and repair instructions can be found at or call CAUTION: Routinely inspect tarp and swing arms, DO NOT operate if parts are worn or damaged. Worn or damaged parts may come loose. Replace all worn or broken parts IMMEDIATELY. WARNING: The swing arms rotate under extreme spring tension and damaged arms could come loose unexpectedly allowing the arm to rotate to with tremendous force. Before any repairs see repair instructions on website for "Properly Releasing Spring Tension" and properly release spring tension. WARNING: DO NOT unlock the roll stops holding the anchor pipe before releasing the spring tension on the AeroForce SS. Unlocking the roll stops can cause a rapid release of spring tension.

44 AeroForce SS Call INDIANAPOLIS, IN Indianapolis, IN FAX: 7-- OMAHA, NE Omaha, NE FAX: KENT, OH Kent, OH FAX: Aero Industries, Inc. PATENT PENDING. Aero Industries, Inc //8 Rev. H