HSP FALCON UTE User manual

Page 1 of 3
AU1, AU2
AU1, AU2
HINGE # 1017
2 x Support Plate 1018
8 x M8 Bolt
8 x M8 Washer
6 x M6 Washers
6 x M6 x 20mm Bolts
23 x Screws (22mm)
2 x Tub Mount 1020
2 x Lid mount gas strut brackets 1041
2 x Self tap ball studs 1040
2 x Lock bracket 1052
2 x Gas struts (400N)
1 x D Mould 1700mm
1 x Alcohol wipe
1 x Instrucon manual
Fitting kit made by :
2 x Lid Front Hinge 1017

Page 2 of 3
AU1, AU2
HARD TONNEAU COVER
FITTING INSTRUCTIONS
MODEL: FALCON UTE
PART NUMBER: AU1, AU2
Please read fitting instructions carefully and completely before attempting to fit your new
Hard Tonneau Cover.
Place the Hard Tonneau Cover onto the ute body and ensure it is sitting correctly on the body with even
gaps all round.
Marked the centre position of each of the front
hinge tonques onto the bedliner and then remove
Hard Tonneau Cover. The marks should be
1190mm apart. Refer to diagram.
Align the centre of the hinge slot brackets supplied
with the marks and attach using the self drilling
screws supplied (4 per hinge).
Measuring along the inside top edge of the tray
880mm and then down 60mm and mark the ball
position for gas strut brackets. Attach gas strut
brackets using self drilling screws. Refer to dia-
gram.
Attach the small shaft end of the gas struts onto
the gas strut brackets.
Attach gas strut brackets onto the Hard Tonneau
Cover using the screws already fitted to Hard Ton-
neau Cover.
With one person on each side, carefully lift the
Hard Tonneau Cover vertical and insert the hinge
tongues into the hinge slots on the vehicle.
Attach the cylinder end of the gas struts onto the
brackets on the Hard Tonneau Cover.
Note: The gas struts may be removed at any time to remove the Hard Tonneau Cover by inserting a small
screwdriver under the metal spring clip on the gas strut end and gently easing it out. You can then
pop the strut off the ball. Never completely remove the spring from the gas strut end.

Page 3 of 3
AU1, AU2
9. Close the Hard Tonneau Cover and check to see if it fits snugly and evenly around both sides and the
back (THERE SHOULD BE A 3 MM MINIMUM GAP TO VEHICLE PAINT WORK ALONG THE SIDES AND
TAILGATE). If it does not, then adjust as follows:
9.1 Open the Hard Tonneau Cover and disconnect the gas struts from the brackets on the Hard Ton-
neau Cover.
9.2 Loosen the 4 Allen key bolts on each of the two hinge tongues.
9.3 One person needs to lie on their back in the utility while the second person closes the Hard Ton-
neau Cover and adjusts the fit by settling the Hard Tonneau Cover into the ideal position. The person in
the Ute then retightens the Allen head bolts before opening the Hard Tonneau Cover.
9.4 Open the Hard Tonneau Cover and reattach the gas struts.
10. Position the lock bracket
as shown and attach using
the screws supplied. Position
screws in the middle of the
slots to allow adjustment.
11. Close the Hard Tonneau
Cover and try the lock. You
may need to adjust the lock
bracket on the tailgate up or
down. When correctly adjust-
ed, you should need to apply
slight pressure to the HARD
TONNEAU COVER in order
to operate the lock.
Do not over-tighten lock or
it will cause damage.
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 AND METHODS AS PER NEW PAINT ON A NEW VEHICLE
Important:
If you have purchased a Central Locking Ute Lid please ignore steps 10 and 11 concerning Lock Bracket
Installation and Lock Bracket adjustment.