AGRI-COVER Tonnosport User manual

Thank you for purchasing TONNOSPORT®Roll-Up Cover. Agri-Cover, Inc. proudly
manufactured this cover using superior quality materials and workmanship. With proper
care, your cover will provide years of service and enjoyment.
NOTICE TO INSTALLER: Even if familiar with cover, read instructions prior to
installation as improvements may be made without notice. Always handle cover and
components with care. If you have questions or problems, have serial number ready and
call customer service. When done, these instructions must be given to the consumer.
NOTICE TO CONSUMER: Before using cover, read operating, maintenance and safety
sections. Save these instructions for future reference.
Questions? 866-630-8726
agricover.com
FOR YOUR RECORDS
DATE PURCHASED:
WHERE PURCHASED:
SERIAL NUMBER:
(Located on decal under rear bar by tailgate)
INSTALLATION INSTRUCTIONS

2
PARTS DIAGRAM
PREPARATION
This document is typically used with trucks that have 78" or longer boxes. Unpack
cover components and clean truck box. For additional installation assistance, go to
accesscover.com for install video.
COMPONENTS
• (6) Clamps
• (2) Driver side rails
• (1) Left and (1) right tension adjuster
with nuts and bolts
• (2) Passenger side rails
• (1) Pre-rolled cover assembly
TOOLS NEEDED
• (2) 1/2” Wrenches
• Marking pen
• Protective eyewear
• Tape measure or ruler
• Torque wrench with 1/2” socket
• Spring clamp - optional
• 1/8” Allen wrench - optional
NOTE: With an under the rail drop-in bed liner, installation is possible with minimal
trimming/cutting of bed liner at front corner of box and back by tailgate to allow side rail
to install properly. Considerable trimming/cutting is required with an over the rail
drop-in bed liner.
NOTE: For additional protection against the elements, locate and seal miscellaneous
factory holes, crevices, stake pockets, etc. that may be in box (sealant not included).
NOTE: Tonneau cover and side rail appearance may vary. Typically a vehicle with a
78" box or longer is provided with two multi-piece side rails.
!CAUTION: Over torquing hardware may damage components.
EZ-DIAL™
Tension Adjuster
Front bar
QUICK CLIP™
Storage Straps Support bows
Slide Locks on
rear bar
Rear bar
Right side rail
Left side rail
Trigger Latch
(6) Rail clamps
Rear
Front (closest to cab)

2 3
1: INSTALLING SIDE RAILS
NOTE: Some installs require special instructions. If required, follow special instructions
for side rail attachment along with these standard instructions.
A. Locate two side rail sections with matching proles displayed in image below.
B. Unroll hook and loop and slide into front side rail channel.
C. Slide front side rail without strike onto pre-installed assembly bracket on rear side rail
with strike.
Front side rail
(without strike)
Rear side rail
(with strike)
Pre-installed
assembly bracket
D. Attach front side rail without strike to assembly bracket with anged hex bolt and
square nut. Align side rails then tighten with 1/2" wrench.
NOTE: Side rails should have little to no gap at assembly bracket.
Square nut
Flanged
hex bolt
Strike

4
1: INSTALLING SIDE RAILS (Continued)
E. Position side rail with weather strip
against inside lip of box. Push side rail
forward until it touches front of box.
IMPORTANT: Ensure strike is positioned
at rear of box.
Top of side rail
ush with top
side of box at
front
Strike at rear
F. At front, adjust top of side rail until ush
with top of box and hold with assistance of
another person or a spring clamp.
G. Install rst clamp as close to front of box
as possible and then use 1/2” wrench to
tighten.
IMPORTANT: To keep side rail secured
on truck, ensure clamp teeth engage
grooves on side rail, turn nut nger tight,
then use wrench to nish tightening.
H. Verify side rail is level. If side rail is not
level, perform one of the following:
If side rail tilts up: loosen and lower clamp,
engage teeth and then retighten clamp.
If side rail tilts down: loosen and raise
clamp, engage teeth and then retighten
clamp.
This surface of
side rail should
be level
Adjust clamps
up or down until
they hold side
rail level when
tightened
Top of side rail ush
with top of box
Temporary
spring clamp
Position
1st clamp
as close
to front
of box as
possible

4 5
1: INSTALLING SIDE RAILS (Continued)
I. Adjust side rail ush with top of box, install second clamp on side rail at midway point.
Repeat clamping procedure.
J. At rear of box, place rear clamp as close to tailgate as possible. Adjust side rail height
until ush with top of tailgate. Repeat clamping procedure.
IMPORTANT: To keep side rail secured on truck, ensure clamp teeth engage
grooves on side rail, turn nut nger tight, then use wrench to nish tightening.
3rd Clamp
2nd Clamp
1st Clamp
NOTE: For trucks with electric tailgates, typically side rail must be installed slightly
higher to eliminate interference.
K. Repeat Step 1 to install side rail on opposite side.
L. Torque all clamps to 20 ft-lbs or value specied in special instructions (if supplied).

6
2: INSTALLING TENSION ADJUSTERS
A. The cover comes pre-rolled in open
position for ease of installation. Set
pre-rolled cover on tailgate with front bar
facing up. Align EZ-DIAL™ Tension Adjuster
(marked “L”) on driver side of cover as shown.
Left
EZ-DIAL™
Nut
B. Turn 1-1/4” bolt with at washer onto nut
in front bar. Leave loose for now. Repeat for
tension adjuster (marked “R”) on passenger
side of cover and leave bolt loose as well.

6 7
3: MOUNTING COVER TO SIDE RAILS
A. Set cover at front of box on side rails
(behind cab) with front bar facing up.
B. Roll front bar onto front side rails and fold/
tuck vinyl ap under front bar. Now, front bar
will face down. Let straps hang inside of box.
Push front bar forward until it sets at on
front of side rails and extends past them.
NOTE: Ensure alignment tabs are positioned
perpendicular to cover.
Alignment tab
C. Slide left tension adjuster until it engages
under side rail (see Step 3F). Push bar
back and forth to line up holes. Do not turn
adjustment wheel. Insert bolt from top and
nut from bottom. Insert bolt
from top

3: MOUNTING COVER TO SIDE RAILS (Continued)
D. Hold bolt at top and tighten nut under side
rail. Repeat Step 3C and 3D for right tension
adjuster.
Tighten nut
Hold bolt
E. Center the front bar between the two side
rails.
Center front bar
between side rails
until space is equal
at both ends
Side rail
NOTE: Before tightening, ensure the vinyl ap
is tucked under front bar.
Vinyl ap tucked
under front bar
Cab
Side rail
F. With the tension adjuster's support tab
under the side rail, tighten bolt (left loose
earlier) under front bar on each tension
adjuster.
Position tab
under side rail
Tighten bolt
8

9
4: INITIAL OPERATION AND ADJUSTMENTS
A. Unroll cover and place rear bar into strikes
on side rails. Press down on rear bar to close
(20-30 lbs pressure). The cover fabric may
be tight. Over time, under tension, it will
conform to its hardware and loosen slightly.
If rear bar is too hard to push down, adjust
tensioners equally as needed to close.
NOTE: If cover is too tight, it may impact
latching mechanism.
Strike at rear
B. Close tailgate slowly, top of tailgate should
t snug under rear bar. If cover impedes
normal tailgate operation, raise side rails by:
loosening rear clamps, adjusting side rail up
and then tightening clamps. If there is a gap
between tailgate and cover, adjust side rails
lower.
IMPORTANT: When done, verify each clamp
is torqued to 20 ft-lbs or value specied
in special instructions (if supplied). Start
behind cab and work toward tailgate.
C. Check cover tension by releasing latch
and then opening and closing rear bar
several times. It should snap when closing.
Cover fabric should be tight without sagging
between the bows.
D. If adjustment is needed, roll cover open
then either: turn tension adjuster clockwise
to loosen or turn tension adjuster counter
clockwise to tighten. Ensure to adjust
tensioners equally.
To Loosen Cover
Turn Clockwise
To Tighten Cover
Turn Counter
Clockwise
E. Always seal both sides of cover with hook
and loop system. For detailed operating
instructions see pages 11 and 12.
Tip: Reasons to keep cover taut:
1. Increases longevity
2. Decreases noise
3. Enhances appearance

10
TROUBLESHOOTING
PROBLEM SOLUTION
Cover too loose Turn both tension adjusters counter
clockwise to move front bar forward (see
Step 4D).
Cover too tight Turn both tension adjusters clockwise to
move front bar back (see Step 4D).
Gap between rear bar and tailgate Side rails set too high (see Step 4B).
Top of tailgate hits rear bar when
attempting to close
Raise side rails at rear of box until
tailgate closes without pushing rear bar
up (see Step 4B).
Cover too narrow Check if side rail is level. If side rail tilts
up: loosen and lower clamp, engage
teeth and then retighten clamp (see Step
1H).
Cover too wide Check if side rail is level. If side rail tilts
down: loosen and raise clamp, engage
teeth and then retighten clamp (see Step
1H).
Lopsided cover (too much on one side) Check if front bar is centered between
side rails (see Step 3E).
Manual Slide Locks too loose or too tight Use 1/8” Allen wrench to tighten or
loosen set screw as desired. Slide Lock
performs best with some friction.

10 11
CLOSING ROLL UP COVER
NOTE: View opening and closing
demonstration video on accesscover.com.
A. Release storage straps at front.
B. Using both hands, unroll cover toward the
tailgate.
C. With tailgate down, position rear bar
against strikes. Push down on rear bar until
trigger latch secures rear bar.
D. On both sides, seal cover edges with hook
and loop system the full length of cover.
Tip: Pull with one hand and seal with other
hand.
E. For additional protection, manual Slide
Locks are located under rear bar on
passenger and driver side. Push Slide Locks
to engage; pull to disengage.

1212
OPENING ROLL UP COVER
NOTE: View opening and closing
demonstration video on accesscover.com.
NOTE:Ensure Slide Locks are disengaged
before opening cover.
A. On driver side, release trigger latch and
rotate rear bar toward cab.
Pull latch
B. Using both hands, roll cover toward the
cab.
C. Secure cover with storage straps.

12 13
• Keep cover closed when not in use.
• Always seal cover edges the full length of box on both sides with hook and loop
sealing system.
• Keep the cover tight; cover should sound drum-like when tapped on.
• Ensure cover is properly latched and sealed.
• Close cover while traveling and before entering automatic drive-through car washes.
• Avoid storing cover in its open position for long periods of time.
• When cleaning, use mild liquid soap and water. Never clean with petroleum or citrus
based products. Petroleum based products may dry out and damage cover vinyl.
• Periodically treat cover with our COVER CARE®Cleaner and UV protectant.
• Whether in open or closed position, ensure cargo does not rub against cover.
TIPS FOR A LONGER LASTING COVER

14
The operator can perform most of inspection and maintenance. It may be necessary to
review the installation and operating instructions.
• Periodically check and/or retighten clamps as needed.
• Periodically check trigger latch to ensure it fully secures rear bar.
• Periodically inspect the condition of cover assembly and all parts. Check for loose
bolts and parts, tighten if needed. Test the operation to ensure parts are functioning
properly and cover is in top operational condition.
• If latch has been damaged, replace with new one.
NOTE: Inspection and/or maintenance should also be performed anytime a malfunction
is observed or suspected. If you need assistance inspecting and/or servicing your
cover call Customer Service at 866-630-8726. If you want to order a replacement part,
call Customer Service or visit accesscoverparts.com. Always use original equipment
replacement parts for your cover.
INSPECTION AND MAINTENANCE

14 15
• Do not cover cargo higher than the cover.
• Do not place object(s) on or against the cover or its framework at any time.
• Always secure cargo to avoid shifting and damaging the cover or its parts.
• Remove snow or debris from top of cover before rolling.
• Do not use the cover’s framework to tie down cargo.
• Never stand, sit or ride on the cover or allow others to do so.
• Do not leave valuables in an unattended vehicle as cover does not prevent theft of
cargo in truck box.
• The cover does not eliminate moisture and dust from entering the truck box. Special
wrappings or packaging of the cargo may be necessary.
• Due to poor ventilation, if you allow a pet/animal in the box, leave cover open. Do not
allow people or animals to occupy box with the cover closed.
• When towing vehicle backward, cover must be rolled fully open and secured with
storage straps.
• Always nish securing the cover by sealing sides.
• Use caution when operating cover in windy conditions.
• Periodically check/retighten clamps and front bar tensioning bolts as needed.
• Periodically check trigger latch to ensure it fully secures rear bar.
SAFETY INFORMATION

MANUFACTURER’S LIMITED WARRANTY
Agri-Cover, Inc. extends the following two (2) year Limited Warranty for the
TONNOSPORT® Roll-Up Cover:
Agri-Cover, Inc. warrants a period of two (2) years from the date of manufacture that its
TONNOSPORT® Roll-Up Cover is free from defects in workmanship, under normal use
for the truck model it was intended for. This Limited Warranty does not cover any damage
due to accident, abuse, misuse, alteration, neglect, improper installation, or ordinary wear
and tear.
Agri-Cover, Inc.’s sole obligation under this Limited Warranty is limited to the repair or
replacement, at its option, of defective parts only. No labor or service allowance is given
or implied. IN NO EVENT SHALL AGRI-COVER, INC. BE LIABLE FOR INCIDENTAL,
CONSEQUENTIAL, OR SPECIAL DAMAGES. AGRI-COVER, INC. EXPRESSLY
DISCLAIMS ANY AND ALL IMPLIED WARRANTIES OF MERCHANTABILITY, AND
THERE ARE NO WARRANTIES WHICH EXTEND BEYOND THE LIMITED WARRANTY
DESCRIPTION CONTAINED HEREIN.
For warranty, ll out the warranty claim form at agricover.com/warrantyclaim or call
Customer Service Department at 866-630-8726 to determine if only a replacement part
is needed or if the cover needs to be returned for inspection and repair. Goods to be
returned must have a pre-authorized RA # (Returned Authorization Number) - obtained by
calling the number above. Mark the number on the package and ship it freight prepaid to
address below. Agri-Cover, Inc. will pay freight to return goods to sender.
This Limited Warranty gives you specic legal rights and you may have other rights, which
vary, from state to state.
For replacement parts shop at accesscoverparts.com or call Customer Service at
866-630-8726.
112818 2000229_
Hours: 8:00 am - 5:00 pm CST Monday through Friday, except Holidays
Agri-Cover, Inc.
Customer Service Dept
PO Box 508 | 3000 Hwy 281 SE
Jamestown, ND 58402
Phone: [phone]
© 2019 AGRI-COVER, INC. ALL RIGHTS RESERVED.
Product subject to change without notice. Patents: agricover.com/patents.