Installation Manual, Usage Tips, & Warranty Information

Transcription

1 Installation Manual, Usage Tips, & Warranty Information Table of Contents 1. Bill of Materials page 2 2. Exploded View of RAIL ASSEMBLY page 2 3. Hardware Pictures page 3 4. Installation: Steps 1 through 10 pages Usage Tips, Technical Assistance, Warnings page 9 6. Warranty page 10 Tools Needed 1. Safety Glasses 2. Power Drill 3. Drill Bits (metal drilling): 3/16 & 7/16 diameter 4. Tape Measure 5. Allen Wrenches: 3/16 & 5/32 6. Socket Drivers: 3/8, 7/16, and 1/2 7. Open-ended Wrench: 1/4 8. Metal marking Punch 9. Small Carpenter s Square AndyMark, Inc

2 Bill of Materials ITEM COMPONENT QUANTITY 1 ASSEMBLED TRAY: Handles, linkage, slide bearings, lock pins 1 2 LEFT RAIL 1 3 RIGHT RAIL 1 4 LEFT RISER 2 5 RIGHT RISER 2 6 CROSS TUBE 1 7 CROSS TUBE INSERT with FOOT 2 8 END-OF-TRAVEL STOP: Rubber cylinder, 5/16-18x1 BHCS w/ Lock Nut & Washer 4 9 CROSS TUBE FOOT SPACER 2 10 LARGE RUBBER WASHER (1+7/8 diameter x 1/8 thick) /16-18 x 2.25 inch FHCS (Flat Head Cap Screw) /16-18 NYLOCK NUT /4-20 x 1.5 inch Hex Head Screw /4-20 COLLAPSIBLE NUT (Gray and bronze color) /4-20 x 1 inch SHCS (Socket Head Cap Screw) /4-20 NYLOCK NUT /4-20 x 3/4 inch SELF-TAPPING SCREW /4 inch WASHER 2 FRONT OF TRUCK 6) CROSS TUBE 3) RIGHT RAIL 5) RIGHT RISER 2) LEFT RAIL 8) END OF TRAVEL STOP 7) CROSS TUBE INSERT with FOOT 3) LEFT RISER BACK OF TRUCK AndyMark, Inc

3 Hardware Pictures Item 7 CROSS TUBE INSERT with FOOT Item 8 END-OF-TRAVEL STOP Item 9 CROSS TUBE FOOT SPACER Item 10 LARGE RUBBER WASHER Item 11 5/16-18 x 2.25 inch FHCS Item 12 5/16-18 NYLOCK NUT Item 13 1/4-20 x 1.5 inch Hex Head Screw Item 14 1/4-20 COLLAPSIBLE NUT Item 15 1/4-20 x 1 inch SHCS Item 16 1/4-20 NYLOCK NUT Item 17 1/4-20 x 3/4 inch SELF-TAPPING Item 18 1/4 inch WASHER SCREW AndyMark, Inc

4 Step 1 Installation Setup 1.1. Clear out a 10ft. x 10ft. area behind the truck bed for layout and assembly 1.2. Ensure all parts are included in your TekTray packages (one long box, one large flat box) as listed on the Bill of Materials Inspect all items for shipping damage 1.4. Remove all material, debris and miscellaneous items from truck bed 1.5. TekTray does not install easily for trucks with drop-in liners. Remove the liner or call technical assistance for more detailed instructions ( ) During installation, before drilling ANY holes, be sure the rail layout is correct Use a small shop-vac to clean up metal debris during drilling. Step 2 Front RISER / CROSS TUBE Assembly 2.1 Slide the CROSS TUBE INSERT with FOOT (item 7) into each end of the CROSS TUBE (item 6) so that the through holes align. 2.2 Position CROSS TUBE below bracket of LEFT RISER (item 4) and RIGHT RISER (item 5). 2.3 Align RISER bracket countersunk hole, CROSS TUBE hole and CROSS TUBE INSERT with FOOT (7). Insert the 5/16-18 x 2.25 inch FHCS (item 11) into hole and apply the 5/16-18 NYLOCK NUT (item 12). 2.4 Repeat for both ends of CROSS TUBE (6). 2.5 Tighten the 5/16 screws to nuts so the RISERS are at right angles to the CROSS TUBE (6). 2.6 This assembled portion of rail structure is now called RISER/CROSS TUBE. Align these holes Step 2.1 Step 2.1 Step 2.2 Step 2.3 Step 2.6 AndyMark, Inc

5 Step 3 Attach RISER/CROSS TUBE to LEFT RAIL and RIGHT RAIL 3.1 Place RISER/CROSS TUBE assembly in front end of truck bed (near cab) to see how this assembly will fit with bed features. RISER/CROSS TUBE assembly can be oriented such that CROSS TUBE (6) is on either side of RISER by rotating RISER/CROSS TUBE 180 degrees. 3.2 Remove RISER/CROSS TUBE from truck bed, and lay it perpendicular to the RAILs. Position RISER/CROSS TUBE on the end of the RAILS with the row of small holes that are 1 inch apart. 3.3 Lift front of RIGHT RAIL (3) and align one hole on RISER/CROSS TUBE with one hole on RIGHT RAIL (3). Use 1/4-20 x 1 inch SHCS (item 15) and fasten 1/4-20 NYLOCK NUT (16) finger tight. Choosing the right hole during this step will set how far RAILs will protrude past the RISER/CROSS TUBE. Various hole mounting locations may need to be tried to find the best fit in the truck bed. 3.4 Repeat step 3.3 for LEFT RAIL using the same corresponding holes. Step 3.3 Step 3.2 RISER/CROSS TUBE & RAIL LAYOUT Step 3.4 Step 4 Install Rear LEFT RISER and Rear RIGHT RISER 4.1 Install LEFT RISER and RIGHT RISER on rear end of RAILs. 4.2 Install two (2) 1/4-20 x 1 inch SHCS (item 15) and two 1/4-20 NYLOCK NUTS (item 16) per RISER. Step 4.1 Step 4.2 AndyMark, Inc

6 Step 5 Finish Fastening Front LEFT RISER and RIGHT RISER 5.1 Fasten front RISERs to RAILs by inserting two (2) 1/4-20 x 1 inch SHCS (15) and two 1/4-20 NYLOCK NUTS (16) per RISER. Tighten all screws and nuts. STATUS CHECK: The RISER, CROSS TUBE, RAIL ASSEMBLY (aka: RAIL ASSEMBLY) is complete. Step 6 Install RAIL ASSEMBLY into truck bed 6.1 Set RAIL ASSEMBLY into truck bed, with CROSS TUBE (6) toward front of truck bed (nearest to cab). 6.2 Align LEFT (2) and RIGHT RAIL (3) ends even with the back edge of the rear vertical bed posts. 6.3 Align RAIL ASSEMBLY so there is a 1/4-1/2 gap between the RAIL end and the tailgate when closed. 6.4 Screw out the FOOT on each end of the CROSS TUBE (6) onto a solid part of the truck bed side wall. 6.5 Adjust FEET on CROSS TUBE (6) so distance is equal between RAILs and side of bed. On wide truck beds, use the CROSS TUBE FOOT SPACER (9). Extend each FOOT tightly against truck bed side wall. 6.6 Close the tail gate, ensuring clearance between RAIL end and tail gate face. Step 6.4 Step 6.1 Step 6.2 Step 7 Front RAIL Spacing Adjustment and Fastening 7.1 Distance from outer edge of LEFT RAIL (2) to outer edge of RIGHT RAIL (3) should be /- 1/ The gap between the outside of RAIL and the truck bed post should be equal from side to side, ranging from 1/8 to 1/2. For each 1/8 of this gap, one LARGE RUBBER WASHER (1+7/8 dia., item 11) will be used as a spacer in step Ensure RISERs are vertical, using small carpenter s square. Drill a 3/16 dia. pilot hole on truck bed post, through the 1/4 dia. hole (closest hole to tailgate) on LEFT RAIL (2) and RIGHT RAIL (3). 7.4 Slide the RIGHT RAIL (3) toward the interior of the truck bed 7.5 Using the 7/16 drill bit, drill through the left truck bed post where marked in Insert 1/4-20 x 1.5 inch Hex Head Screw (item 13) into left RAIL hole (with 1/4 inch WASHER, item 18), add the correct number of LARGE RUBBER WASHERs (10) on the outside of the RAIL (see step 7.2). 7.7 Insert the 1/4-20 COLLAPSIBLE NUT (item 14) onto the end of the 1/4-20 x 1.5 inch Hex Head Screw (13), screwing the NUT onto the screw. AndyMark, Inc

7 Step 7.1 Step 7.1 Step 7.3 Hole Step 7.5 Steps 7.6, Push the 1/4-20 COLLAPSIBLE NUT (14) into the 7/16 hole. 7.9 Tighten the 1/4-20 x 1.5 inch Hex Head Screw (13) until the LARGE RUBBER WASHERs (10) and the 1/4-20 COLLAPSIBLE NUT (14) is tight between the RAIL and the truck bed post Repeat steps , for mounting the LEFT RAIL to the right truck bed post. Step 7.8 Step 7.9 STATUS CHECK: Both RAILs are fastened to back truck bed posts. The front ends of each RAIL not to be fastened to the truck bed sides. Verify the outside to outside RAIL dimension is 59.5 after RAIL fasteners have been installed. AndyMark, Inc

8 Step 8 Fasten RISER Feet to Bed Floor TIP: The RISER foot plate can be bent to form to the ribs in the truck bed. 8.1 Inspect all four (4) RISERs so they are vertical and in proper location, using a small carpeter s square. 8.2 Choose two (2) holes at each RISER foot location for fastening holes, drilling a 3/16 diameter pilot through the bed floor at those two (2) locations for each RISER foot. 8.3 Insert two (2) 1/4-20 x ¾ inch SELF-TAPPING SCREWs (item 17) into the drilled holes for each foot. Tighten screws with 3/8 Socket Driver. Step 8.1 Step 8.3 STATUS CHECK: RISER feet are all fastened to truck bed floor, by means of 2 screws each. Step 9 Install the ASSEMBLED TRAY (This is a two-person task) 9.1 Lift the TRAY and align the bearing groove (located on either side of TRAY bottom), fitting into the bottom of the LEFT and RIGHT RAIL. Insert the TRAY with handles facing out. 9.2 Push the TRAY forward, turning the lock handles clockwise, drawing the lock pins inward, allowing the TRAY to move completely into the bed on the RAILS. 9.3 Release lock handles, allowing spring-loaded lock pins to insert into the rear set of RAIL lock holes. 9.4 Confirm that the pins fully protrude through the RAIL lock holes, sticking out of the black plastic blocks on both sides. If not, check steps 2-8 and re-position RAILS for proper spacing and height. 9.5 Lock the TRAY in the front postion, and inspect the lock pin insertion as in step 9.5. Step 9.3 Step 9.2 Step 9.1 Extended pin STATUS CHECK: TRAY should glide freely on RAILs, moving with 5-7 pounds of push force. Ensure TRAY easily locks with both pins in front and rear locking positions. AndyMark, Inc

9 Step 10 Install the END-OF-TRAVEL STOPS 10.1 Push TRAY completely forward, toward the truck cab Locate one (1) 5/16 diameter hole in RIGHT RAIL(3), 15 inches from the back end of the RAIL Install the END-OF-TRAVEL STOP (item 8) through the inside face of the rail, with the nut being on the outside of the RAIL. Secure and tighten Repeat for LEFT RAIL Pull out TRAY, until END-OF-TRAVEL STOPs (8) limit the travel Locate one (1) 5/16 diameter hole in LEFT RAIL (2), 41.5 inches from the front end of the RAIL Install the END-OF-TRAVEL STOP (8) into this hole, just as done in step Repeat for RIGHT RAIL (3) Step 10.2 STATUS CHECK: END OF TRAVEL STOPS will now limit Tray from being removed from RAILS and from hitting the front bed wall. TekTray is fully installed. Usage Tips To extend bearing life and performance, clean RAIL sliding surface periodically. If mud, sand, or other debris get into bearing areas, wash out with water and remove any debris. Technical Assistance For parts or technical assistance, call AndyMark, Inc. at or For new information, please check the website. Warnings Step 10.6 Lower tailgate before unlocking tray Lock tray before moving vehicle Do not unlock tray on incline Maximum load 750 pounds Never move a vehicle without making sure the TRAY is locked in front or rear position The TekTray concept and design is protected by U.S. Patent # AndyMark, Inc

10 TekTray Limited 3 Year Warranty AndyMark, Inc. guarantees that this product is free from defect in workmanship and materials from three years of the date of the purchase of product. AndyMark, Inc will not be responsible for any defect which has resulted from normal wear, misuse, lack of maintenance, or alteration made or specifically authorized by anyone other than authorized service centers or installation centers. Product must be registered for this warranty to have effect. The product must be returned to origin of purchase with proof of purchase and explanation of return. If inspection of the parts verifies a defect in workmanship and/or materials the product will be repaired or replaced at our election. If product cannot be quickly replaced and/or repaired we may refund the purchase to the buyer. Please fill out the Warranty Registration Card below and send to this address: AndyMark, Inc. 700 E. Firmin St. #114 Kokomo, IN TekTray Warranty Registration Card First Name: Last Name: Address: City: State: Zip: Phone Number: Vehicle Make: Year: Vehicle Model: Indicate Type of Use (Circle) : Commercial Personal Purchasing Location: City: State: or if by Internet Order: Order # TekTray Serial Number: Purchase Date: Comments: AndyMark, Inc