Roll-n-Lock 110 User manual

August 29, 2011
PRODUCT CODES:
100, 105, 110, 111, 112, 113, 115, 120, 130,
140, 145, 146, 150, 200, 210, 240,
250, 255, 260, 300, 305, 405, 406,
407, 408, 425, 426, 435, 447, 500,
505, 510, 800, 805, 810, 820,
825, 826 &827
INSTALLATION GUIDE
STANDARD

page 2
INSTALLATION GUIDE
STOP!
I F YOU HAVE A PLASTIC
DROP - IN BEDLINER , BE
SURE TO FOLLOW S TEP 1
ON THE NEXT PAGE .
I F NO BEDLINER IS
PRESENT , PROCEED TO
S
TEP 2.
TOOLS NEEDED COMPONENTS INCLUDED
Tailgate
Extrusion
Clamp(s) x 6-8
Pull Strap
Cargo
Shield
Drain
Tube(s) x 2
Housing
Hinged Lid
Track(s) x 2
3/8" Drill
1/2" Drill Bit
#2 Philips Screwdriver
P2 Tip

page 3
S TEP 1: B EDLINER M ODIFICATION
Note: If the truck is
equipped with a plastic
drop-in bedliner, some
alteration will be necessary.
If no bedliner is present,
proceed to Step 2.
A. The dotted lines in
Diagram 1 depict
the more common
under-the-rail liner
modifications.
1. Using a jig saw with
a medium tooth
blade, remove the
bulkhead portion
of the liner as
indicated.
2. Be sure to trim
the bedliner’s
plastic tailgate
panel as shown.
B. The dotted lines in
Diagram 2 depict
the less common
over-the-rail liner
modifications.
1. Using a jig saw
with a medium
tooth blade,
remove the top
cap and bulkhead
portions of the liner
as indicated.
2. If a rear notch is
necessary, place
the Tracks on
their respective
bedrails and mark
the positions of the most rearward Clamps prior
to removing the liner. (The correct position of the Track is with the black
plastic Track End-Cap touching the inside surface of the tailgate.)
3. When the modification is complete, push the wall of the liner under the
bedrail.
4. Be sure to trim the bedliner’s plastic tailgate panel as shown.
(2)
1/2
" DIAMETER HOLES
for drain hoses,
located as required
TAILGATE PANEL
BEDLINER
CUT
2"
6
1/4
”
(Shortbed)
7
1/4
”
(Shortbed)
8
1/4
”
(Longbed)
5"
Typical
under-the-rail
bed liner
BEDLINER
5"
NOTCH (as necessary
for rear clamp)
1/2"
6
1/4
”
(Shortbed)
7
1/4
”
(Shortbed)
8
1/4
”
(Longbed)
TAILGATE PANEL
(2)
1/2
" DIAMETER HOLES
for drain hoses,
located as required
CUT
2"
Typical
over-the-rail
bed liner
Diagram 1
Diagram 2

page 4
S TEP 2: I NSTALL THE H OUSING
A. If desired, install the Stake-Pocket Hole
Covers where necessary (Photo 3).
B. Place the Housing Assembly onto the bedrails
(Photo 4). This is best accomplished with two
people. Center it between the bedrails and
leave about ½" of space between the bulkhead
and the back of the Housing.
Do not fasten the Housing in place.
C. Lift the
Lid on the
Housing
and lean
it against
the cab.
(Photo 5)
Place a rag
between the
Lid and cab
to prevent
scratches.
Photo 3
Photo 5Photo 4
S TEP 3: I NSTALL THE T RACKS
A. Making
sure to
leave the
Pull Strap
connected
to the
threaded
shipping
stud,
rotate
the Lock
Lever to the
10 o’clock position (Photo 6).
B. Remove the “L”-shaped sections of Clamps
that are taped to the bottoms of the Track
Clamps
(Photo 7). Because these are
location-specific, be sure to lay them
in the bed in the same order as you
remove them from the Tracks.
C. Carefully place the Tracks on the bedrails
(Photo 8) and key them onto the Housing Stems
(Diagram 9), being sure that the Handle is properly engaged into the Tracks.
Photo 7Photo 6
Photo 8

page 5
S TEP 3: I NSTALL THE T RACKS ( CONTINUED )
D. Attach
the back
Clamps very
loosely to
the Tracks
to be sure
that the
Tracks do
not fall off
of the bed
rail while
proceeding (Photo 10).
E. Use #10-24 x ½" truss head screws and
Cargo Nuts to secure the Tracks to the
Housing Stems (Photo 11). Tighten these
connections securely.
F. Attach the remaining Clamps very loosely.
Do not tighten yet.
Photo 10
S TEP 4: I NSTALL THE T AILGATE E XTRUSION
A. Lower the tailgate and use a tape measure
to locate and mark the center of the tailgate
(Photo 12).
B. Use a tape measure to locate and mark the
center of the Tailgate Extrusion (Photo 12).
C. While holding the Tailgate Extrusion square
and centered on the tailgate, use a #8 x ¾"
self-tapping screw and power screw gun to
secure the hole nearest center (Photo 13).
Next, move to each end,
press the Tail gate
Extrusion to the top of the tailgate in order
to make it conform to the contour of the
tailgate, and secure it in place.
D. Install the remaining self-tapping screws,
making sure to provide even spacing between
them.
E. With the Tailgate Extrusion secured, carefully
close the tailgate, being cautious not to strike
the ends of the Tracks.
Photo 12
Photo 13
Photo 11
Truss Head Screws
Cargo Nut
Track
Housing
Stem
Diagram 9
Track
Housing
Stem

page 6
S TEP 6: I NSTALL C ARGO S HIELD & D RAIN T UBES
A. Trim the track gasket 1" from the end of the
Track (Photo 18).
B. Rotate the Lock Lever to the 7 o’clock (closed)
position (Photo 19), then remove the plastic
wing nut and detach the Pull Strap from the
threaded Stud (Photo 20). Pull the Cover
closed and latch it to the tailgate.
Note: Do not allow the Cover to retract
while the Housing Lid is open.
C. Before lowering the Housing Lid, turn the Lid Pin Knobs ¼ turn clockwise,
which will cause the pins to pop in if they are not already. Lower the Housing
Lid, being sure that the Lid Pins snap into the receptors located on the Tracks.
S TEP 5: O RIENTING THE T RACKS TO THE T AILGATE
A. Move to the front of the bed, lift up slightly on
the Housing and shift each side back toward
the tailgate (Photo 14) so that the Track End-
Caps contact the inside surface of the tailgate.
Make sure the Track End Cap Metal Blocks
contact the Tailgate Extrusion End Caps
(Diagram 15).
Note that if the Tracks are not positioned
as shown, the Latch Mechanism will not
function correctly.
B. With the
Tracks in
the correct
position, you
may now
tighten the
Clamps in the
order shown
(Diagram
16), taking
care to make
sure the Tracks remain level.
Do not use a power or pneumatic screw
gun. Over tightening Track Clamps can
cause an indentation in the bedrails.
C. If the Track pitches upward, loosen the Clamp,
rotate the Track level and install the optional
Angularity Adjustment Screw as shown
(Diagram 17). Tighten the screw until it biases
against the bedrail down-flange as shown.
Photo 14
TIGHTENING SEQUENCE
➛
➛
➛
➛
➛
➛
➛
➛
➛
TIGHTEN 2nd
TIGHTEN 2nd
TIGHTEN 3rd
TIGHTEN 3rd
TIGHTEN 4th
TIGHTEN 4th
TIGHTEN 1st
TIGHTEN 1st
TAILGATE
Diagram 16
90 APPROXIMATELY
ANGULARITY ADJUSTMENT SCREW
(FOR ADJUSTMENT ONLY)
Diagram 17
Photo 18
Diagram 15
Track
Tailgate
Extrusion

page 7
S TEP 6: I NSTALL C ARGO S HIELD & D RAIN T UBES
D. To open the
Cover pull
back slightly
on the Handle
to relieve
spring tension
from the Latch
Mechanisms
and turn the
Lock Lever
clockwise to
the 10 o’clock
(unlatched)
position.
E. Use 1/4-
20 x 1/2" truss
head screws
and rubber
washers to
secure the
Cargo Shield
(Diagram 21).
Note: The rubber washers go on the inside of the Cargo Shield.
F. Use 1/2" bit to drill 2 holes for the Drain Tubes. Note that this process is easier if
1/4" pilot hole is drilled first. Align the holes with the Drain Fittings that protrude
from the bottom of the Housing Assembly (Photo 22). If provided, locate the
Drain Tubes in factory drain holes or bulkhead plugs.
G. Always make sure the Pull-Strap is securely clipped to a fixed point in the bed.
Photo 19
Photo 22
Photo 20
Diagram 21
Cargo
Shield
Truss Head Screws
Rubber Washers
S TEP 7: T EST U NIT O PERATION
In Step 6 the Cover was opened (retracted). This should have caused the Lock
Lever to enter the Lock Pocket and rotate to the 7 o’clock (latched) position.
A. To close the Cover, pull the Pull-Strap hand-over hand, allowing the excess
strap to fall into the bed until you can reach the Handle. Place your hands
evenly spread on the Handle and pull the Handle until it contacts the Tailgate
Extrusion. As the Handle contacts the Tailgate Extrusion the spring loaded
Latches (which were energized when the Cover was retracted) will automatically
trip, simultaneously latching the Cover to the tailgate and side Tracks.
B. To open the Cover, pull back slightly on the Handle to relieve spring tension
from the Latch Mechanisms and turn the Lock Lever clockwise to the 10 o’clock
position. The Cover should retract on its own with only a slight push to set it into
motion. When the Cover is retracting it is best to hold the Pull-Strap and allow it
to slip through your fingers as the Cover travels. Applying pressure to the Pull-
Strap as it slips through your fingers will act as a braking action, preventing the
Handle from slamming into the Lid at high speed. The Cover must retract with
only enough force to rotate and reset the Lock Lever and Latching Mechanism.

S TEP 8: O PENING AND C LOSING / A DJUSTING
THE H INGED L ID
To Open:
A.
Grasp the Latch Pin Knobs, pull out and turn
knobs 90° to hold Pin in the unlock position.
Grasp the Lid and lift. Rest the Lid against
the back of the cab to hold open for service or
cleaning (Diagram 23).
To Close:
A. Lower the Lid and return the Latch Pins to
locked position by turning the knobs 1/4 turn.
If Lid is loose:
A. Raise Lid and loosen the nylock nut on each
Lid Latch Bracket, move the top half of the
Bracket one notch toward the tailgate. Tighten
both nuts and close Lid (Diagram 24).
If Lid is tight:
A. Raise Lid and loosen the nylock nut on each Lid Latch Bracket, move the top
half of the Bracket one notch toward the Housing. Tighten both nuts and close
Lid (Diagram 24). Repeat if futher adjustments are needed.
Lid Knob
Back
of
Cab
Diagram 23
Nylock Nut Latch
Track
Diagram 24