TONNEAU INSTALLATION GUIDE

Transcription

1 Warranty, are & Maintenance Model Model Ford Ford Flareside Sport Short Trac ed ESY S 1-2-3! FORM # IG2050 IG2060 Modified June September NORML INSTLLTION TIME 30 MINUTES

2 Page 1 PRE-INSTLLTION NOTES e sure to use only cleaners, waxes, etc., which are labeled Safe for Plastics. Make sure that chemicals or substances, which are not labeled safe for plastics, do not come in contact with your Undercover. Failure to do so could cause discoloration and/or structural damage to your Undercover and will void your warranty. Paint rubbing of the truck is normally not a problem, but is always a possibility with any tonneau. To ensure less chance of possible paint rubbing of the truck, it is suggested to install a tailgate protector and adhere ab Skin, Scotch al, or similar product to the truck bed. These products can provide added assurance against paint rubbing. Undercover Tonneaus are designed from trucks that do not have a bed liner (spray-in bed liners pose no problem). Trucks that do have under-the-rail or over-the-rail bed liners will require some minor trimming of the bed liner to ensure proper placement of the mounting brackets. ue to the wide variety of bed liner manufacturers, the modifications will vary slightly between different brands. ny modifications must be made to the bed liner and NOT to the Undercover mounting hardware. Modifications to the mounting hardware will result in improper installation and will void your warranty. INSTLLTION KIT HEKLIST : Hydraulic Struts : Stainless Steel olts 5/16 x 1 1/4 : J-Hooks & Wall Mounting Screws : Spiral lamps Rings E: Spiral Forward Rings Mounting rackets* F: Stainless Rear Mounting Steel rackets* Washers 5/16 G: all Stainless StudsSteel Lock Washers 5/16 H: Lock Forward Washers Mounting rackets I: Rear Washers Mounting rackets J: Mylar Tabs * See iagram on Page 4 for racket H, I and lamping Hardware E F G HE H F E J G H I I I FRONT

3 Page 2 UNEROVER INSTLLTION TOOLS NEEE 3/8 WRENH OR SOKET 1/2 WRENH OR SOKET QUIK REMOVL & REINSTLL REVIEW NORML INSTLLTION TIME 30 Note: If your Tonneau has already been installed, skip to Page 9 for removal and reinstall instructions. MINUTES Off your truck and on your wall in less than one minute! Underover makes tonneaus for most makes and models of trucks.

4 ESY S UNEROVER INSTLLTION INSTRUTIONS Page 3 STEP 1 Rear Mounting racket FT: Undercover is the lightest hardshell tonneau in the industry. Only 58-pounds for full size trucks. Place the rear bracket against the truck bed stake using pocket 6mm or bolts tail light with well lock Page washers 4, Figure and fl 1, at Pictures washer in&. existing holes. See iagram, Figure 1. Use two of the holes in rear bracket which are unobstructed by the truck bed, (there will be three to choose from), Repeat one Step hole for as opposite far forward side as of possible truck bed. and one hole as far back as possible (this will vary depending upon truck model) Page 4, Figure 2. Place a 5/16 x 1 1/4 bolt with a 5/16 lock washer and a 5/16 washer through the hole in bracket Page 4, Figure 3. Place clamp on backside of bracket behind the bed lip of the truck. Thread the bold into the clamp and tighten being careful to not let the clamp twist while tightening. Make sure bracket is held down tightly against truck bed rail before tightening. Repeat procedure for second clamp. Mounting bracket bolts must be tightened down without bending the bracket. Keep the clamps straight and do not let them turn while tightening Page 4, Figure 3, Picture &. WRNING! olts must be tightened to the correct torque to prevent any movement of the bracket on the truck bed. olts must be re-checked for tightness periodically. Failure to do so could cause serious damage to both the truck and/or your Undercover. Repeat Steps through for opposite side of the truck bed. Footnote: Normal installation does not require the use of a torque wrench. ut it is a good idea to compare how tight you are currently tightening the bolts with the tool you are using with a torque wrench just so you can get the feel of how tight 15-ft./lbs. or 180-in./lbs. of torque actually is.

5 UNEROVER INSTLLTION INSTRUTIONS Figure 1 TOP VIEW RER RKET TRUK E RIL FRONT RKET Page 4 10 TIL GTE RER RKET TILGTE LOK STRIKE TRUK STKE POKET OR TIL LIGHT WELL ULKHE Figure 2 ERIL RER RKET RIVER S SIE UTWY VIEW LOK STRIKE Figure 2 LL STU 1 2 Model 2060 Ford Flareside Short ed Proper position for olt Screws and lamps. 3 LIGHT WELL/ STKE POKET TIL GTE Figure 3 5/16" x 1-1/4" HEX HE OLT RER RKET E LIP TRUK E RIL RER RKET USING 6mm OLTS WITH LOKWSHERS N FLT WSHERS IN EXISTING HOLES IN E SIE. LMP RKET 5/16" LOK WSHER 5/16" WSHER Model 2050 Ford Sport Trac LMP INSTLLE ORRETLY LMP INSTLLE INORRETLY

6 ESY S UNEROVER INSTLLTION INSTRUTIONS Page 5 STEP 2 Front Mounting racket & all Stud Front Mounting racket FT: Undercover s S-omposite material makes it the strongest and most durable tonneau on the market. Position the front bracket according using 6mm to bolts Page with 6, Figure lock washers 4, Picture and fl. at It washers is very important in existing to holes reviewin bed Page side. 6, Repeat Figure for 4 for opposite the proper side. gap Page distance 6, Figure to set 3 the front brackets of your truck model. Included WRNING: in Truck your kit beds is a may ball vary stud, and Page could 6, Figure require 4, adjustment used to attach to the your front hydraulic brackets shock. which pre-treaded in hole is already turn could provided affect on the your gap bed. distance Just screw between in the ball bulkhead stud on and both the 5, sides front of bracket. the bed. The e designated sure and use the washer gap and in lock Figure washer 4 is provided a good starting your kit. point The before hole is adjustments located about may halfway be necessary. between Refer the front to Page and 7, rear of your bed. Step e 3, sure Section and do not to make overtighten necessary the stud adjustments. because you could shear it off with too much pressure. Using WRNING! designated o not holes overtighten in Page all 6, stud. Figure Overtightening 5, place a 5/16 could x 1 twist 1/4 stud bolt off. with a 5/16 lock washer and a 5/16 washer through the hole in bracket. Place clamp on backside of bracket behind the bed lip of the truck Page 6, Picture. Thread the bolt into the clamp and tighten being careful to not let the clamp twist while tightening. Make sure bracket is held down tightly against truck bed rail before tightening. Repeat procedure for second clamp. Place tonneau Mounting on bracket truck positioning bolts must female be tightened hinges down on tonneau without over bending tangs the on front bracket. brackets Keep and the clamps straight install spiral and do rings not into let holes them turn in tangs while on tightening. front brackets This procedure Page 6, Figure is the 6, same Picture as in. Step. Two 1 when 1/4 assembling round bolts clear and Mylar clamps decals on the are rear included brackets. to help See prevent Page the 6, Picture spiral rings & from. rubbing the truck on models that fit close to the cab. E SURE TO INSTLL SPIRL RINGS EFORE TTHING THE HYRULI STRUTS IN STEP 3. Repeat Steps & for opposite side of the truck bed. Place tonneau on truck positioning female hinges on tonneau over tangs on front brackets and install spiral rings into holes in tangs on front brackets Page 6, Figure 6, Picture. Two 1 1/4 round clear Mylar decals are included to help prevent the spiral rings from rubbing the truck on models that fit close to the cab. E SURE TO INSTLL SPIRL RINGS EFORE TTHING THE HYRULI STRUTS IN STEP 3. Modified September June

7 UNEROVER INSTLLTION INSTRUTIONS Figure 43 Install front bracket using 6mm bolts with lockwashers TRUK and fl at E washers RILin existing holes in bed side. Page /16 from end of bulkhead. Proper starting point for model 2060 Ford Flareside Short ed TOP VIEW Position edge of bracket 1/8" back from FRONT RKET front edge of bulkhead. ULKHE Figure 54 SPIRL RING HOLE ULKHE TNG E LIP FRONT RKET TRUK E RIL Remove upper bolt and install all Stud with lock washer and fl at washer. UTION: O NOT overtighten all Stud Model 2060 Ford Flareside Short ed Model 2050 Ford Sport Trac Proper position for olt Screws 2000 and 2005 lamps. Figure 65 TNG 4 MYLR TS are placed on your cab in front of spiral ring SPIRL RING FEMLE HINGE UNEROVER TONNEU TOP VIEW

8 ESY S UNEROVER INSTLLTION INSTRUTIONS Page 7 Final STEP 3 Installation Steps FT: In less than one minute, you can both take on and off the Undercover tonneau. Fastest removal system in the industry. Install hydraulic struts making sure LRGE end of strut is attached to the tonneau, and SMLL or rod end is attached to the ball stud on attached rear bracket to your Page bed Page 8, Figure 8, Figure 7, Picture 6, 7, Picture.. e sure that the front flap seal hangs over the bulkhead of the truck and is not rolled under the tonneau after installation. If flap seal is rolled under the tonneau, open the tonneau and from the inside use a yardstick or something similar to push the flap seal out from under the tonneau and over the bulkhead Page 8, Figure 7, 8, Picture. lose tonneau and check length on the truck. There should be 1/8 -to- 3/8 gap between the tailgate and the tonneau. If this is not correct, adjust by moving front brackets forward or back to achieve correct length. Front brackets may also have to be adjusted independently to square-up tonneau on some truck beds. djust lock strikes Page 8, Picture. When adjusted properly you should be able to turn the key to the locked position without having to push down on the tonneau. There should be a very slight amount of play between the lock cam and lock strike. good rule of thumb is to adjust the lock to have approximately 1/8 gap between the cam and lock strike with the truck tailgate down. This usually gives you the proper adjustment after the tailgate is shut Page 8, Figure 8, 9, Picture. WRNING: It is very important to be able to turn the key without any resistance. o not try to force the lock cam to turn if you encounter resistance. This could result in a broken key or broken lock. djustment may be necessary to the lock strike plate to achieve a smooth turn without any resistance.

9 UNEROVER INSTLLTION INSTRUTIONS Figure 76 On Sport Tracks, the ball stud is not on the rear bracket, but located on the bed. See Page 6, Figure 4 TRUK E RIL HYRULI STRUT (LRGE EN) TTHES TO TONNEU HYRULI STRUT (RO EN) Page 8 30 RER RKET Figure 87 UNEROVER TONNEU FRONT FLP SEL INORRET PLEMENT OF FRONT FLP SEL ORRET PLEMENT OF FRONT FLP SEL: FLP HNGS OVER ULKHE TRUK ULKHE Figure 98 LOK LOK STRIKE RER RKET TRUK E RIL LOK M #10-24 WIZ NUT 5/16"-18 X 1-1/4" HEX HE OLT 5/16" LOK WSHER 5/16" WSHER E LIP LMP

10 1 Minute Removal UNEROVER REMOVL & REINSTLTION INSTRUTIONS Page 9 Your 30-minute installation job is now complete. Now, in less than one ongratulations! minute, you will be able to put on and take off your tonneau cover. Step 1 Release strut off of ball stud. Holding tonneau up with one hand, place loose end of strut on storage clip. Repeat for the other side Picture &. Step 2 With cover closed, remove spiral rings at the front of the tonneau. E SURE TO HVE STEP 1 OMPLETE FIRST Picture. Step 3 Now carefully remove the tonneau off of the truck bed Picture G. 1 Minute Re-Install Step 1 Place tonneau on the truck bed positioning hinges over front bracket tangs Picture. Step 2 Install spiral rings on tangs to secure cover Picture. Open tonneau with and attach strut to ball stud Picture &. E G F UNEROVER TONNEU INORRET PLEMENT OF FRONT FLP SEL Step 3 e sure that the front flap seal is hanging over the bulkhead, not rolled under the tonneau after installation Picture E & F.

11 Page 10 UNEROVER WLL HNGING INSTRUTIONS Step 1 Prior to removing the tonneau, mount the two J-Hooks provided on the garage wall. The hooks must have a minimum height from the floor of 70, and be 32 on center horizontally apart Picture &. Step 2 Remove your tonneau from the truck bed according to instructions on page 9, 1-Minute Removal Step 3 Hang tonneau vertically on the wall-mounted J-Hooks, with the underside against the wall inserting J-Hooks into the holes provided in Picture.

12 UNEROVER SERIL NUMER LOTION The Serial Number sticker is located on the left rear of the tonneau, just under the back overhang. THNK YOU! ongratulations! You ve just installed the fastest-selling, highest-quality tonneau in the industry. Thank you very much for your purchase of Underover! Steve rallier President E.. Industries/Underover E.. Industries/Underover P.O. ox 620 Rogersville, MO (417) (866) E.. Industries, Inc. ll rights reserved.