Tuff Tonneaus 10522 Install guide

TONNEAU FITTING INSTRUCTION
Isuzu D-Max Dual Cab With Head Board
Jul 2012 to Current
Part number: 10522
Package includes
 1 X Tonneau cover  2 x Bar Brackets (300474)
 1 x Tonneau Support Bar (300516)  28 x Rivets (300482)
 1 x Rope Track 1253mm (With Shim)  1 x Lock Bracket
 1 x Support Bar Sheath  16 x Rope Buttons (300473)
 1 x Fitting Instructions  2 x Dowel
 1 x Warranty Card  4 x M8 Bolt (S 0050)
 1 x LH Front cnr seal plate A300118
 1 x RH Front cnr seal plate A300119

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Table of Contents
1. TONNEAU COVER FITTING .............................................................................................................. 3
1.1 BASIC TOOL REQUIRED ................................................................................................................. 3
1.2 TONNEAU COVER INSTALLATION PROCEDURE ............................................................................ 3
2. TONNO LOCK ................................................................................................................................... 6
2.1 BASIC TOOL REQUIRED ................................................................................................................. 6
2.2 TONNO LOCK CONTENTS .............................................................................................................. 6
2.3 FITTING TONNO LOCK ................................................................................................................... 6
3. MULTI FIT SUPPORT BAR ................................................................................................................ 7
2.1 BASIC TOOL REQUIRED ................................................................................................................. 7
2.2 MULTI FIT SUPPORT BAR CONTENTS ........................................................................................... 7
2.3 FITTING MULTI FIT BAR ................................................................................................................ 7

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1.
1.1.
1. TONNEAU COVER FITTING
TONNEAU COVER FITTINGTONNEAU COVER FITTING
TONNEAU COVER FITTING
NOTE
Read entire instructions prior to start.
1.1 BASIC TOOL REQUIRED
1.1 BASIC TOOL REQUIRED1.1 BASIC TOOL REQUIRED
1.1 BASIC TOOL REQUIRED
Drill, 4mm Drill Bit, Rivet Gun, Marking Pencil / Pen
1.2 TONNEAU COVER
1.2 TONNEAU COVER 1.2 TONNEAU COVER
1.2 TONNEAU COVER INSTALLATION PROCEDURE
INSTALLATION PROCEDUREINSTALLATION PROCEDURE
INSTALLATION PROCEDURE
NOTE Remove swarf and a ly the rovided Rust Inhibitor to all drilled holes rior to
riveting. Read entire instructions rior to start.
1. To attach seal plates, remove the top bolt on each side of the inside edge that secures the head
board. Place the seal plate against the inside of the head board and relace bolt. DO NOT
TIGHTEN YET.
2. Align the seal plate so the top surface sits level with the top front edge of the tub. With 4mm
drill bit, drill a hole in the front face of the tub through the existing hole in the seal plate on
each side. DO NOT RIVET YET.
3. Remove seal plate and clean swarf from the tub and seal plate. Apply a bead of silicone to the
back of the seal plate. Reposition seal plate against the front face of the tub. Insert 4mm rivet
and rivet into place. Tighten bolts in head board.
4. Place one piece of dowel in each end of the rope track. Rest rope track and dowel on the top
edge of the seal plates. Ensure the flat side of the rope track is the surface positioned against
the tub face. See F gure 1.
5. Drill 4mm hole through each of the holes in the rope track into the front edge of the tub. Place
a 4mm rivet in each hole as it is drilled. DO NOT RIVET YET. Once all holes have been drilled,
remove the rivets, rope track and dowels.
6. Apply a bead of clear silicone along the centre of the front edge of the rope track (the side that
contacts the tub).
7. Rivet the aluminium rope track into position.
8. With the pencil mark the inside edge on each side of the tub at 740mm from the inside front
face of tub towards the rear on each side. Centrally locate the bar bracket over this position
and align the top of the bar bracket 10mm down from the top edge of the tub and drill and
rivet bracket into place. See F gure 2. Repeat for other side of tub. Fit tonneau support bar to
bar brackets.

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9.
Slide the front of the tonneau cover through the alumin
i
um rope track section.
10. Ensure tonneau s centred. To fit the rope buttons to the tub, start with the ta lgate, vertically
line up each button to each bunji loop starting from the centre bunji loops. The height for the
buttons on the tailgate is 410mm UP from the bottom edge of the tailgate. Work from the
centre out, alternating from side to side. Attach each bunji to the button as it is fitted.
11. To fit the rope buttons to the sides, vertically line up each button to each bunji loop starting
from the rear bunji loop, alternating from side to side working towards the front. The height for
the side rope buttons are all measured down from the TOP INSIDE EDGE of the tub. For the
rear button measure 160mm, 165mm for the second button from the rear, and 170mm for the
next two buttons. For the button closest to the front of the tub measure 175mm down and
25mm back from the front edge of the tub. Attach each bunji to the button as it is fitted.
NOTE: All measurements are to be taken from the TOP INSIDE EDGE of the tub.
12. To fit Velcro to the tub release the front bunji on each side. Fold the cover back to reveal the
hook side Velcro (attached to the loop side on the cover). Peal the backing from the velcro and
fold back onto the top edge of the tub. ALLOW 30 MINUTES FOR THE VELCRO TO ADHERE.

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F gure 2: Placement of
bar bracket
F gure 1: Placement of
aluminium rope track.
Ensure channel is above
the tub’s top edge.
10mm down
from top edge
of tub
740mm