HSP B15 User manual

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B15
B15
2 x Support Plate 1018
8 x M8 Bolt (25mm)
8 x M8 Washer
4 x M6 Large washers
4 x M6 Spring washers
4 x M6 x 40mm Bolts
6 x M6 20mm Bolts
6 x M6 Washers
23 x Screws (22mm)
2 x Lid mount gas strut bracket 1041
2 x Self tap strut mount 1040
2 x Lock bracket 1072
2 x Gas struts (250N)
1 x Alcohol wipe
1 x Instrucon manual
1 x FBA Bar (PX)
Fitting kit made by :
2 x Lid Front Hinge 1017B

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B15
• Pen / Marker • Die Grinder & multi tool • Soapy water solution
• Centre Punch • Masking Tape • Allen Key set (Metric)
• Drill & Drill bits • Scissors & Knife
• Phillips head screwdriver • Ruler
• Caulking Gun • Spanner & Socket
• Silicon - Non Acetic • Tape measure
• Read Instructions fully before commencing installation.
• Clean Tonneau Cover with a mild detergent and water solution
• Do not use abrasive cleaners or solvents
• Refer to manufactures instructions applicable to power drill.
• Protect Tub floor against scratches during installation process.
Check contents of kit before commencing fitment and report any discrepancies
Fitting Instructions Part Number B15
Mazda BT-50 Dual Cab 2011+
To suit Sports Bars
If lubrication of the locks or hinges is required use only Graphite Powder. DO NOT use any other
lubricants or oils.
• Do not stand/sit or rest heavy objects on Tonneau Cover
• Humans or animals are not to be under the closed Tonneau at any given time
• Securely lock tonneau Cover before operating vehicle
• Tonneau Cover is not dust or water tight
• Do not carry open volatile chemicals with Tonneau Cover installed
• If contact with volatile chemicals occur, clean Tonneau with mild detergent and water solution
Tools Required
Maintenance
Care Instructions
IMPORTANT
Parts List Qty Pre-Fitted
Hard Tonneau Cover 1
Infill Panel 2
Gas Struts (250N) 2
Front Hinge 2
Hinge Support Plate 2
M8 Washer 8
M8 Bolt 8
Lock Bracket 2
Self Drilling Screw 13 
Lid Strut Bracket 2
M6 Bolt 6
M6 Washer 6
Front Body attach bracket 2
Lock Set 2
Tonneau corner pieces 2
Cleanseal 1
*Image example shown only

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B15
Installation Steps Flow Chart
START
SPORTS BAR REMOVAL
TUB PREP FOR LID INSTALL
LID INSTALL AND ADJUSTMENT
FINISH

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B15
Note: Two people are required to complete the installation.
Pull the Stop Lamp wiring Loom from the hole in the front left hand corner of the vehicle tub, where the front left hand
side foot is located and disconnect the Connector. Remove the Sports Bar and retain all the hardware.
Thoroughly clean installation areas.
Find the centre of the bed and mark the position.

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B15
Hinge mounts:
Align the hinge mounts along front of tray, ensuring the hinges are properly positioned from centre of tub TBD mm
to centre of hinge mount either side along the inside of the front of tub. Attach the hinges using self-drilling screws
(supplied) through holes pre-drilled into the hinges. Apply clear or black silicone to any gaps and between the hing-
es and the vehicle to prevent water entry.
TBD TBD
Measure and mark the positions as indicated above from the centre of the bed for placement of the bottom hinges.
WARNING: RECHECK DIMENSIONS TO ENSURE CORRECT MEASURENT
Drive the self-tapping screws through the holes in the top and the base of the hinge plate into the tub. Tighten to
3Nm.
Gas Struts:
Measure from the front rail inside of tub, measure along top edge of tray TBD mm (windscreen end) then down
20mm and mark the screws position for the gas strut bracket. Position the gas strut bracket accordingly,
mark two mounting holes and centre. Refer to Fig. 1 and Fig. 2
TBD mm
Fig.1 - Gas strut bracket location
20 mm
Fig.2 - Gas strut bracket location

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B15
Using a 2 mm diameter drill bit set to 5 mm drill stop. Drill two pilot holes. Attach small gas strut bracket using self
drilling screws provided. Repeat process on other side of tray. Refer to Fig. 2 and Fig.3
Fig.3 - Gas strut bracket fitment
Attach small shaft end of gas strut onto gas strut brackets, by clicking them in place.
Refer to Fig.4 with regard to gas strut orientation.
Fig.4 - Gas strut orientation
Fig. 5- Hard Cover strut bracket
location
With the lid on the floor and taking care to prevent damage or scratches to the painted surface, fit the upper gas strut
mounting brackets to the lid using 20mm M6 Screws and Washers.
Refer to Fig. 5
Important:
DO NOT over tighten screws. Recommended tightening torque is 1- 3 Nm

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B15
Clean header rail (where extrusion will sit) with alcohol wipes provided and wipe away residue with a dry clean cloth.
Place the extrusion tape seal along the top of the header rail with the sealing lip facing towards the tailgate. Start the
extrusion at the edge of the side rail. IMPORTANT: Position extrusion as close to the header rail rear radius. Rub
down firmly to ensure maximum adhesion.
Important:
DO NOT over tighten screws. Recommended tightening torque is 1- 3 Nm
START EXTRUSION
AT EDGE OF SIDERAIL
NOTE: SEALING LIP
MUST FACE TAILGATE

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Remove all four caps from the Sports Bar. Remove protective lining from foam gaskets provided and adhere them to
underside of rubber feet cups of the Sports Bar. Apply a bead of non acetic silicon (not supplied) around the inside
surface of the foot cap. Replace the foot cups. NOTE: On left hand front foot cut foam gasket to accommodate wiring
loom to pass out of the Sports Bar.
IMPORTANT: Be careful not to scratch the painted corner pieces when fitting them to the Sports Bar.
Install the corner piece using the M6X20 hex head screws and M6 large flat washers as shown. Do not tighten at this
point to allow adjustment of position once installed to vehicle. Repeat for the other side of the vehicle.
Carefully position the assembled sportsbar and corner pieces onto the tub, taking care not to scratch the vehicle.
NOTE: Two people are required to lift into position.

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B15
Reinstall Sports Bar to vehicle. Tighten all previously removed Sports Bar screws to torque 15Nm. Tighten screws
between corner pieces and sports bar. Repeat for the other side of the vehicle.
Connect the Stop Lamp wiring and push back into the hole in the tub.

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Fitting the Hinges:
Place hinges in front bar slots and secure hinges with
hinge pin. With the aid of an assistant place lid on the car
with Tailgate Down.
NOTE: Take care not to damage Hard Tonneau or vehi-
cle.
From inside the tub, place hinge support followed buy the
8 washers and bolts (Supplied) into holes and hand tight-
en.
Check each side of the lid to make sure that there is the
same clearance between the lid and the tub. Tighten the 8
bolts to the specified torque. With the assistance of one
other person holding the lid open connect the gas struts to
the lid gas strut mounts.
Remove painted lid from the box. Turn the lid upside-down and put the lid in on a Stand. Remove hinges from the
lid.
Important:
Ensure tongues are fully inserted into the hinge slots with hinge pin securely in place.
Check clearance of tonneau cover to vehicle rear corners. Ensure the tailgate is open and close tonneau cover.
Check clearances at both rear corners between tonneau cover and sheet metal. Gaps should be consistent. If tonneau
cover is touching sheet metal or gaps are not even, adjustment of the tonneau position may be required.

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Fig. 9 - Attach gas strut
With the Hard Tonneau Cover opened, attach the cylinder end of each gas strut onto the mounting brackets
attached to the Hard Tonneau Cover by clicking into place
Refer to Fig. 9
Important:
If you have purchased a Central Locking Ute Lid please ignore the next page concerning Lock Bracket
Installation and Lock Bracket adjustment.

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B15
Important:
This page for Manual Locking lids ONLY
Please skip this page if you have purchased a Central Locking Lid
Lock Brackets:
To fit lock brackets, open tailgate and close Hard Tonneau Cover. Make a mark where the lock cam (arm) lines up
with the sides of the tub. Open Hard Tonneau Cover to install lock bracket. Position lock bracket and using a 2 mm
diameter drill bit set to 5 mm drill stop to drill a pilot hole in each vertical slot of the bracket. Ensure that there is
allowance for up and down adjustment of the bracket. Fasten bracket with self-drilling screws (supplied) ensuring
thread installs into metal of Ute rail, again allowing for up and down adjustment. Refer to Fig. 11
Fig. 11 - Install lock bracket
Close the Hard Tonneau Cover and try the locks. You may need to adjust the lock brackets on the Ute tub up or
down. When correctly adjusted, you should need to apply slight pressure to the lid in order to operate the locks.
Refer to Fig. 12.
Fig. 12 - Lock bracket adjustment
Important:
Excess tension could damage the lock.

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FIGURE 1
1. Open tonneau cover. Disconnect harness at front
Header bar. Detach gas strut (1) by inserting a small
screwdriver and adjusting the spring clip (2) on the
gas strut(1). Refer to figure 2.
NOTE: Do not remove the spring clip, only a
small amount of levering is required to detach. FIGURE 2
NOTE: 2 people are required to lift and re-
move the tonneau cover from the vehicle.
2. Remove hinge pins (1) and remove tonneau cover (2).
Refer to figure 3.
REMOVAL OF TONNEAU COVER
FIGURE 3

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Having trouble? Call your Supplier.
NOTE: Please ensure Lid is kept locked at all times when not being used, for both safety and longevity.
Paint care instructions:
Your new painted Hard Tonneau Cover has been covered with a plastic film to protect the paint from damage. It will
require cleaning and possibly light polishing after the protective film has been removed. Use polish as per new paint
on a new vehicle. Wash Hard Tonneau Cover using water and normal carwash detergent and polish with an automo-
tive polish.
FIGURE 4
NOTE: 2 people are required to lift and fit the
tonneau cover onto the vehicle.
1. Fit tonneau cover (2) and secure hinges
with hinge pins (1). Refer to figure 5.
FIGURE 5
2. Attach gas struts (2) by clipping into place. Ensure
narrow end (1) mounts to the vehicle. Reconnect har-
ness at front header bar. Refer to figure 6.
REPLACEMENT OF TONNEAU COVER
FIGURE 6