SOFT TONNEAU COVER INSTALLATION

TC0155
SOFT TONNEAU COVER
INSTALLATION INSTRUCTIONS
Care Instructions:
Clean Tonneau Cover with a mild
detergent and water solution.
4.1460.0341
Do not use abrasive
cleaners or solvents.
PLACE THESE INSTRUCTIONS IN VEHICLE’S GLOVE BOX AFTER INSTALLATION IS COMPLETE.
IMPORTANT
WARNING!
Securely lock Tonneau Cover or Draw Back and Securely Tie Back before operating vehicle! Failure to do so could result in unexpected opening of the
Tonneau Cover from sudden wind gusts, which could cause damage to the vehicle and/or your Tonneau Cover!
Maintenance
Your EGR Tonneau Cover only requires periodic cleaning with water, neutral car wash soap and sponge or flannel. Never use any chemicals or
abrasive products to clean your EGR Tonneau Cover. Always use the Central Crossbars to give support and facilitate water drainage.
The latch mechanisms only require occasional lubrication with Graphite Powder. Using alternative lubricants or oils, will void warranty.
All installation Clamps must be reguarly checked and tightened if required.
IMPORTANT!
• Do not stand/sit or rest heavy objects on Tonneau Cover.
• Do not carry Sharp or Pointed Material, or Material that exceeds Bed Height with Tonneau Cover closed.
• Humans or animals are not to be under the closed Tonneau Cover at any time.
• Securely lock Tonneau Cover before operating vehicle.
• Do not carry open volatile chemicals with Tonneau Cover installed.
• If contact with volatile chemicals occurs clean Tonneau Cover with mild detergent and water solution.
• Read instructions carefully before installation. It is strongly recommended that installation is conducted by an authorized dealer.
• This product must be installed exactly as specified in these instructions. Failure to do so may result in improper fit and/or retention.
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TC0155
SOFT TONNEAU COVER
4.1460.0341
COMPONENTS LIST
NO. COMPONENT
1.
2.
QTY
1 Front Rail, Cover, Corner Piece Assy
1
2 Front Rail, Cover, Corner Piece Assy Cabin Guard
1
3 Side Rail Assy LH
1
4 Side Rail Assy RH
1
5 Clamp Assy (’A’ Deck)
6
6 Clamp Assy Kit (’J’ Deck)
1
7 Cross Bar
2
8 Cabin Guard Seal
1
RECOMMENDED TOOL LIST
Phillips Head Screwdriver
Cleaning Materials
3.
4.
10mm Spanner
ITEMS
DESCRIPTION
1
5.
6.
x6
x6
x6
x6
x12
x6
x30
3
4
5
6
7
8
‘A’ DECK NO CABIN GUARD
7.
x6
2
8.
‘A’ DECK WITH
CABIN GUARD
‘J’ DECK NO CABIN GUARD
x6
‘J’ DECK WITH
CABIN GUARD
‘A’ DECK CROSS SECTION
page 2 of 8
‘J’ DECK CROSS SECTION
INNER TUB
INNER TUB
VEHICLE OUTER PANEL
VEHICLE OUTER PANEL
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TC0155
SOFT TONNEAU COVER
4.1460.0341
FOR ‘J’ DECK
MODELS ONLY
1 CLEAN AND DRY
INSTALLATION AREAS
2 FIT (3) NUT BLOCKS
TO EACH SIDE RAIL
SIDE RAIL (LH)
1. Thoroughly clean and dry the installations areas.
If fitting a ‘J’ Deck model, Fit three (3) Nut Blocks from the [Clamp Assy Kit (’J’ Deck)] to the LH Side Rail and repeat
for the RH Side Rail.
LAY COVER 3
OVER CABIN
VEHICLES FITTED WITH A CABIN GUARD
2 POSITION FRONT
RAIL, COVER & CORNER
PIECE ASSY
FIT COVER SO
FRONT RAIL SEALS
ON CABIN GUARD
4 TIE BACKS
IN TUB
FIT CABIN
GUARD SEALS
TOP VIEW
CABIN
SEAL GUARD
TOP VIEW
1
OPEN REAR TAILGATE
CABIN
SEAL GUARD
2. Open Rear Tailgate. Position Front Rail, Cover & Corner Piece Assy at the Front of the Tub on the Bedrail, with the cover
carefully layed over the Vehicle Cabin. If Cabin Guard is fitted, first fit cabin guard seals to cabin guard and cut to length
as shown IMPORTANT: Ensure seals are fitted exactly as detailed above to prevent any rubbing, which could
result in possible paint chipping. Align notches on Front Rail Cover Assy with Cabin Guard Bars as shown.
NOTE: Ensure Tie Backs are positioned inside the Tub as Shown Above.
1 POSITION SIDE RAILS
LH AND RH ON BEDRAIL
1 POSITION SIDE RAILS
LH AND RH ON BEDRAIL
2
ORIENT SIDE RAILS
SO LATCH MOUNTS FACE
TO REAR OF VEHICLE
2
ORIENT SIDE RAILS
SO LATCH MOUNTS FACE
TO REAR OF VEHICLE
NO BEDLINER
FITTED
BEDLINER
FITTED
3. Position Side Rail Assy’s LH & RH on the respective Bed rail Sides Ensuring Latch Mounts are orientated to the Rear
of the Vehicle as shown above.
NOTE: If your vehicle is fitted with a Bedliner please proceed to Step 4, If your vehicle does not have a
bed liner please proceed to Step 5.
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TC0155
SOFT TONNEAU COVER
4.1460.0341
STEP 4 ONLY APPLIES TO ‘A’ DECK VEHICLES FITTED WITH A BEDLINER
2 REMOVE COVER AND
SIDE RAILS
7 POSITION COVER AND
SIDE RAILS
4 MARK AND CUT-OUT NOTCHES
1
5 DEBURR ANY SHARP EDGES
3 REMOVE BEDLINER
6 REFIT BEDLINER AND
CHECK CLAMPS FITMENT
4. Using clamp location stickers on the Side Rails, mark a centerline on the Bedliner where the Clamps will be located.
Remove Cover & Side rails, then remove the Bedliner. Measure the height of the vehicle rails and mark a rectangle on
the Bedliner to enable the clamps to be fitted to the vehicle. Cut out marked areas on Bedliner and deburr any sharp
edges. Refit Bedliner to the vehicle and check that the Clamps can be fitted. Position the Front rail, Cover and corner
piece assy and Side rails as per steps 2 & 3.
1
2
3
COVER
COVER
TUB
LOOSEN
SCREW
COVER
SIDE
RAIL
CORNER
PIECE
SIDE
RAIL
TUB
TUB
TIGHTEN
SCREW
FIT SIDE RAIL
TO CORNER PIECE
5. Loosen Screw (ensuring it does not dis-engage from the Nut) on each side of the Front Rail Corner Piece Assy’s as
shown. Slide Side Rail Assy’s LH & RH into the Front Rail Corner Piece Assy’s ensuring they are fully engaged as shown.
Tighten Screws on both sides to firmly clamp Side Rails to Front Rail as shown above.
STEP 6 ONLY APPLIES TO ‘A’ DECK VEHICLES
1
3
2 ALIGN FRONT RAIL ASSY TO FRONT
OF BEDRAIL OR CABIN GUARD
TIGHTEN
CLAMPS
10mm
6. Loosely fit three (3) Clamp Assy’s per side, aligning them with the clamp location stickers on the Side Rails as shown.
Align Front Rail Assy to the Front Bed rail or Cabin Guard (if fitted) and Centralise so both Side Rail Assy’s sit evenly
on the Bed Rails as shown. Finger tighten all clamps.
Using a 10mm Spanner, tighten the front clamps closest to the cabin. Position cover over the Tub and read steps 9 & 10
to fit cover to the side rails. With the cover attached to the side rails Align one side to the bedrail and tighten the rear
clamp. Position the other side rail on the bedrail, ensure the cover is pulled tight across the vehicle tighten the other rear
clamp. Remove the cover as detailed in step 11 and 12, tighten the (2) remaing clamps so the Side Rails are firmly
attached to the Vehicle.
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TC0155
SOFT TONNEAU COVER
4.1460.0341
STEP 7 ONLY APPLIES TO ‘J’ DECK VEHICLES
1 ALIGN FRONT RAIL ASSY
NUT PLATE
AS PER STEP 6 (ITEM 2)
NUT BLOCK
SIDE RAIL
TO NUT BLOCK
BOLT
M6x25
3 CUT-OUT & FIT
TEMPLATE
L CLAMP
BRACKET
BOLT
M6x20
Z CLAMP
FLAT BRACKET
WASHER
2 FIT BOLT M6x20, FLAT
ALIGN TOP EDGE
TO TOP OF TUB
4 MARK, DRILL
Ø6mm HOLES (X2)
WASHER AND Z CLAMP
BRACKET
6 TIGHTEN BOLT
FLAT
WASHER
FLAT WASHER (X2)
SCREW M5x20
(X2)
NUT
5 FIT L CLAMP BRACKET, (2)
SCREWS M5x20, (2) FLAT
WASHERS AND NUT PLATE
7 FIT BOLT M6x25, FLAT
WASHERS AND NUT
7. Align Front Rail Assy to the Front Bed rail or Cabin Guard (if fitted) as per step 6 (item 2). Loosely assemble Z clamp
bracket, Bolt M6x20 & Flat Washer to Nut Block in Side Rail, align to clamp sticker on Side Rail as shown. Cut-out and
position template (from page 8) as shown aligning to the Z Clamp bracket and the top edge to the top of the bedrail. Mark
and drill two (2) Ø6mm holes. Remove template. Install L clamp bracket with 2 screws M5x20 and nut plate supplied as
shown. Tighten Screws M5x20 to Nut Plate and Bolt M6x20 to Nut Block. Install one (1) Bolt M6x25 and Nut, and two (2)
Flat Washers to secure Side Rails to the vehicle. Finger tighten all Nuts. Repeat process for three (3) clamps per side.
Using a 10mm Spanner and adjustable spanner, tighten the front clamps closest to the cabin. Position cover over the Tub
and read steps 9 & 10 to fit cover to the side rails. With the cover attached to the side rails Align one side to the bedrail
and tighten the rear clamp. Position the other side rail on the bedrail, ensure the cover is pulled tight across the vehicle
tighten the other rear clamp. Remove the cover as detailed in step 11 and 12, tighten the (2) remaing clamps so the Side
Rails are firmly attached to the Vehicle.
2 ROTATE TO LOCK
INTO POSITION
CROSSBARS TO BE
EQUALLY SPACED
OVER TUB
1 FIT CROSSBARS
TO SIDE RAILS
8. Some vehicles require different length Cross bars, If the Cross Bars are marked Front & Rear ensure the Front Cross
Bar is installed closest to the Cabin & the Rear Cross Bar closest to the Tailgate. If there are no markings then the
Cross Bars are the same length and can be installed Front and Rear. Install Crossbars evenly spaced by sliding into
Side Rails at an angle & rotating till they run across the vehicle. NOTE: Crossbars must be fitted as instructed to
assist Water Drainage. Failure to fit Crossbars may result in Damage.
3 PRESS DOWN
FIRMLY
1 ROLL COVER
OVER THE TUB
COVER
2
FOLD FLANGE
UNDER SIDE
RAIL EDGE
SIDE RAIL
9. Roll Cover over the Tub towards the rear of the Vehicle. Fix the Cover to the Side Rails by folding the Flexible Flange on
the Cover outwards and rolling them in under the edge of the Side rails as shown above. To lock them in Press Down
firmly on the outside of the Cover as shown above.
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TC0155
SOFT TONNEAU COVER
4.1460.0341
3 PRESS DOWN UNTIL
LATCHES CLICK
COVER
LATCH
2
ROLL DOWN
TO REAR OF
VEHICLE
LATCH MOUNT
1 POSITION LATCH
INTO LATCH MOUNT
4
CHECK COVER IS
LOCATED IN SIDE RAILS
10. Position Latches into Latch Stretch Mounts as shown above. Holding the Cover Rail at the Rear Roll towards the Rear
of the Vehicle and Down until Latches Click and Both are Locked into Position.
Check that the entire length of the Cover Side Flexible Flanges are firmly located into the Side Rails.
INSTRUCTIONS TO REMOVE SOFT TONNEAU COVER
COVER
2 TWIST COVER
1 PUSH TO FULLY
RELEASE LATCH
1 PULL HANDLE DOWN
11. Open Rear Tailgate.
Locate Latch Pull Tab Under the Cover in the middle, and Pull in a Downward Direction to Disengage Latches, Twist the
Covers Rear Rail in an upward and forward direction to Completely Release the Latches.
1 LIFT UPWARD
COVER
2
RELEASE FLANGES
FROM SIDE RAIL
SIDE RAIL
12. Working from the Rear to the Front of the Vehicle, Grip & Lift in an upward direction the Sides of the Cover to Release the
Flexible Flanges from the Side rails.
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TC0155
SOFT TONNEAU COVER
4.1460.0341
1 ROLL COVER
TO FRONT OF TUB
Ensure Black side
of cover is on the
outside when
rolling up
2 SECURE WITH
TIE BACKS
13. Roll Cover inwards to the Front of the vehicle and secure with the Tie Backs.
IMPORTANT: Ensure Black side of cover is on the outside when rolling up as it is UV Protected.
IMPORTANT
DO NOT CLOSE THE REAR TAILGATE WHEN TONNEAU COVER LATCHES ARE ENGAGED.
When Closing the Vehicle Tailgate Ensure the Tonneau Cover Latches are Dis-engaged First,
then close the Tailgate.
Re-engage the Latches and ensure that the entire length of the Cover Side Flexible Flanges
are firmly located into the Side Rails as per step 10.
TONNEAU COVER
3 ENGAGE LATCH &
PRESS DOWN UNTIL
LATCHES CLICK
1 DIS-ENGAGE LATCH
2 CLOSE REAR TAILGATE
4
CHECK COVER IS
LOCATED IN SIDE RAILS
A. To Close Rear Tailgate Dis-engage Latches as per step 11, then Close Rear Tailgate.
Re-engage the latches and ensure that the entire length of the Cover Side Flexible Flanges are firmly located into
the Side Rails
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TC0155
SOFT TONNEAU COVER
4.1460.0341
DRILL TEMPLATES FOR ‘J’ DECK VEHICLES ONLY
TOP OF
BEDRAIL
TOP OF
BEDRAIL
DRILL
Ø6mm
DRILL
Ø6mm
TOP OF
BEDRAIL
TOP OF
BEDRAIL
DRILL
Ø6mm
DRILL
Ø6mm
TOP OF
BEDRAIL
TOP OF
BEDRAIL
DRILL
Ø6mm
DRILL
Ø6mm
100mm when printed
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