Diamondback HD User manual

Important installation information
PRE-INSTALLATION NOTES:
IMPORTANT!
Keep an eye out for these icons:
Normal Install Time
60 minutes
Tips to assist installation
Helpful Hints
1. Install the Bulkhead Prep Kit before installing
your DiamondBack cover. Refer to the Bulkhead
Prep Kit Installation Guide for details.
3. If you are installing a Side-Loading ATV Carrier
on cargo bed longer than 6 feet, you must mount
the center panel adapter bars prior to installing
your DiamondBack HD. Refer to the Side Adapter
Bars Installation Guide for details.
2. If you are installing a Low-Profile Cab Guard
or HD Cab Guard, you should mount it prior to
installing your DiamondBack. Refer to the Cab
Guard Installation Guide for details.
POSITION THE PANELS
Finger-tighten the cap clamps at
each corner of the center panel.
2To avoid hinge damage, do not close the
panel until hinges are fully mated: Tilt the
panel past 90° and push to the left until the
hinge lock tabs interlock.
The bottom halves of the cap
clamps should be in the deck
rail system.
Mating hinges is
easiest when you
line up the longer,
left hinge pin first.
4. It’s possible for one person to install a DiamondBack
solo, but the whole process, especially positioning
the panels and adjusting the lock rods, is much
easier with two people.
Repeat step three for the
tailgate panel.
4
Position the cover
front to back so that
the leading edge of the
cab panel lines up with
the leading edge of the
bulkhead.
5
CONTINUED ON OTHER SIDE
Place the center panel across the
center of bed, cheated slightly toward
the tailgate.
1
Make the sure the
arrow sticker on the
underside of the
center panel is
pointing toward the
tailgate.
Slide the cab panel onto the center panel by mating their hinges. Close the
cab panel slowly. Make sure it doesn’t hit your cab.
3
Center the DiamondBack cover
side to side on the truck.
6
Tighten the cap
clamps with a
9/16” socket.
7
Retighten your clamps after 100
miles. Check them every time
you haul on top.
Cap Clamps (4)Gas Springs (4)
Safety Catch
Grommets (2)
Cab Panel
Tailgate Panel
Center Panel
PARTS INCLUDED:
TOOLS REQUIRED:
1/8”
Hex Key
7/16”
Socket
9/16”
Socket
Ratchet Wrench
INSTALLATION GUIDE
[phone] | DIAMONDBACKCOVERS.COM 2005-UP TOYOTA TACOMAS
with the 60.3" Bed
Drill 1/8” or
3/16” Bit 1” Bit Marker

ATTACH THE SAFETY CATCH & GAS SPRINGS
ADJUST THE LOCK RODS
16
Attach the three remaining gas springs
(barrel up, shaft down).
18
Leave the cover closed and locked for 24
hours to allow the weatherstrip adhesive,
which is pressure-sensitive, to fully cure.
19
MARCH 2015WWW.DIAMONDBACKCOVERS.COM
To ensure the best weatherstrip adhesion, leave your cover and tailgate
closed and locked for 24 hours after you’ve made your final adjustments.
11 Open the tailgate panel. Drill the
marks with a 1/8" or 3/16" bit.
13
Repeat at the opposite
corner.
12
Drill the marks again with a 1" bit. Insert a
grommet into each hole.
14
Close the tailgate panel. Repeat steps 8 through 10 for the tailgate
panel using the new holes instead of the deck rail system.
15
Your panels should be very difficult to operate at first. Leave them closed
as much as possible for 3–4 days to break in the weatherstrip. After that
period, you should find that the panels open and close without difficulty.
Loosen the set screws on the
cab-panel lock rod linkages.
ADJUST THE CAB-PANEL LOCK RODS:
ADJUST THE TAILGATE-PANEL LOCK RODS:
1/8” Hex Key
7/16” socket
Attach a gas spring to the
same ball studs.
17
To avoid premature
failure of your gas
springs, attach them
barrel up, shaft down.
Fit the safety catch around the ball studs on
the driver side of the cab panel.
To ensure the safety catch
works properly, attach it as
shown with the slotted half up
and triangle pointing toward
the cab.
Adjust the length of the lock rods and retighten
the set screws so that:
A.
B. The ends of the lock rods point
toward the bed floor.
9
8
Position the lock rods tight
against the underside of the
deck rail system so that
they’ll draw the panels
down and compress the
weatherstrip. Tighten the
rod guide brackets with a
7/16" socket.
10
To get the weatherstrip compression
necessary for its adhesive to cure and the
cover to keep out the weather, have a
second person press down on the cover
while you’re adjusting the lock rods.
Using the access
panels is easiest
when you press
down as you open or
close them.
To avoid lock handle damage, don't
let the ends of your locking rods
touch the bed wall.
With the lock handle in the closed postion,
the rods travel as close as possible to—but
no more than—1½" past the underside of the
deck rail system.
Have a second person press down on a rear
corner of the cover. Under the same corner, hold
the rod guide bracket so that its bolts are at the
midpoint of its vertical slots. Mark the points on
the bed wall where the lock rods will hit.