Tuff Tonneaus 524 Installationsanleitung

TONNEAU FITTING INSTRUCTION

Toyota Hilux Dual Cab SR5

2003 to Mar 2005

Part number: 524

Package includes

1 X Tonneau Cover

2 x Bar Brackets

1 x Tonneau Support Bar

28 x Rivets

3 x Aluminium Rope Track-484mm long ea.

1 x Lock Bracket

1 x Support Bar Sheath

14 x Rope Buttons

1 x Fitting Instructions

4 x Dowel

14 x Anti Abrasive Discs

1. TONNEAU COVER FITTING

NOTE Read entire instructions prior to start.

1.1 BASIC TOOL REQUIRED

Drill, 4mm Drill Bit, Rivet Gun, Marking Pencil / Pen

1.2 TONNEAU COVER INSTALLATION PROCEDURE

1. Using two pieces of dowel, join the 3 aluminium rope tracks together. Place the other 2

pieces of dowel in the ends of the now joined rope track.

2. Rest the aluminium rope track on the side rails as Shown in Diagram A, and push forward to

the vertical face of the tub.

3. Using a 4.5 mm drill bit, drill 6 holes 50mm from the end of each of the aluminium rope

tracks into the front of tub.

4. Once all the holes have been drilled, remove the dowelling pieces. Squeeze silicon along

the back of the rope tracks and pop rivet into place.

5. To fit bar brackets measure 680 mm from the inside edge at the front of the tub and place

them as shown in Diagram A. (5mm down from top edge of tub). Drill and rivet using 4

rivets. Insert support bar.

6. To fit round body hooks to car measure 115 mm down from top edge and line up each hook

individually to each bunji (loop) starting with the two either side of the tail gate handle and

working your way around to the front, drill and rivet buttons alternating from side to side.

7. To Fit Anti-Abrasive Discs: Firstly clean the area behind each bunji head with a clean rag

and methylated sprits. Then attach the anti-abrasive discs centrally behind each bunji head.

Diagram A

2. TONNO LOCK

The Tonno Lock is now a standard feature included with all

Tuff Tonneaus. The Tonno Lock is situated at the front of

the tonneau cover, so as not to impede the accessibility of

the Tuff Tonneau.

Fitting the lock is simple and only requires a small

attachment on the inside edge of the tub behind the cab.

Together with a padlock, it provides you with an extremely

effective theft deterrent. The Tonno Lock is designed to suit

all utes and prevent thieves stealing your Tuff Tonneau, so you can continue to rely on the Tuff Tonneaus’

name to give you what you want in a tonneau cover.

2.1 BASIC TOOL REQUIRED

Rivet gun, Drill, Torch, and Marking Pencil/Pen.

You will need to buy a small Padlock- make sure the padlock will go through the hole on the Tonno lock.

2.2 TONNO LOCK CONTENTS

-2 X 4MM Aluminium rivets

-1 x Tonno Lock bracket

2.3 FITTING TONNO LOCK

1. Attach the black lock bracket to the bracket on the tonneau with your padlock, and fit the tarp.

2. Getting under the tarp with a torch, place the lock bracket against the body and mark holes with a pen.

3. Remove tonneau and drill the marks with a 4 mm drill bit, place the lock bracket in position and rivet.

Diagram B

3. MULTI-FIT SUPPORT BAR

The Tuff Tonneau Multi - Fit Support Bar is designed to fit almost all

Utes on the Market, from Suburu Brumbys to Cab Chassis aluminium

trays.

3.1 BASIC TOOL REQUIRED

Drill, 4mm drill bit

3.2 MULTI-FIT SUPPORT BAR CONTENTS

-1 x hollow bar centrepiece - 2 x grub screws

-2 x solid bar end piece - 1 x Tonneau bar sheath

3.3 FITTING MULTI-FIT BAR

1. Insert solid bar pieces into either end of hollow tube. Adjust bar so it fits between bar bracket

holders with the holes facing to the ground (so the grub screws don’t rub against the tonneau), as

shown above and then with a white pencil make a mark through the small holes of the hollow bar

onto the solid ends. This is where you will drill a hole to the depth of about 1-2mm (do not go any

further)

2. Join the pieces back together and screw grub screws through the hollow bar into the holes that you

drilled. Make sure you do not over tighten the grub screws. Then place the tonneau

sheath over the bar to stop the bar wearing against the tonneau. Refit the bar. You may kink the bar

in the middle to give it some extra height to assist with water runoff.

Warning if you do not fit the tonneau sheath over the bar, the tonneau cover will quickly wear through

which is not covered by warranty.

4. WARRANTY AND FEEDBACK

Please register your warranty details online at:

QR Code:

Website Link:

http://www.tto.com.au/en-au/warranty.html

Please complete our 2 minute feedback section as we strive to constantly improve

for our customers.

Your Tuff Tonneau is now ready for work.

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