Tuff Tonneaus 660 User manual

TONNEAU INSTALLATION INSTRUCTION
Ssangyong Actyon, April 2007 - Current
Part number: 660
Package includes
 1 X Tonneau cover  4 x Bar Brackets (300474)
 2 x Tonneau Support Bar (300517)  30 x Rivets (300482)
 3 x A uminium Rope Track-526mm ong ea.  1 x Lock Bracket
 2 x Support Bar Sheath  18 x Rope Buttons (300473)
 1 x Fitting Instructions  4 x Dowe
 1 x Warranty Card

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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 ................................................................................................................................... 5
2.1 BASIC TOOL REQUIRED ................................................................................................................. 5
2.2 TONNO LOCK CONTENTS .............................................................................................................. 5
2.3 FITTING TONNO LOCK ................................................................................................................... 5
3. MULTI-FIT SUPPORT BAR ................................................................................................................ 5
2.1 BASIC TOOL REQUIRED ................................................................................................................. 6
2.2 MULTI-FIT SUPPORT BAR CONTENTS ........................................................................................... 6
2.3 FITTING MULTI-FIT BAR ................................................................................................................ 6

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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
Dri , 4mm Dri Bit, Rivet Gun, Marking Penci / Pen
1.2 TONNEAU COVER INSTALLATION PROCEDURE
1.2 TONNEAU COVER INSTALLATION PROCEDURE1.2 TONNEAU COVER INSTALLATION PROCEDURE
1.2 TONNEAU COVER INSTALLATION PROCEDURE
1. Using two pieces of dowel, join the aluminium rope tracks together. Place the other 2
pieces of dowel in the ends of the now joined rope track.
2. Rest the aluminium rope track on the side rails as Shown in Diagram A, and push forward to
the vertical face of the tub.
. Using a 4.5 mm drill bit, drill 6 holes 50mm from the end of each of the aluminium rope
tracks into the front of tub.
4. Once all the holes have been drilled, remove the dowelling pieces. Squeeze silicon along
the back of the rope tracks and pop rivet into place.
5. To fit bar brackets measure 640mm back from the inside front edge at the top of the tub and
place them as shown in diagram A. (5mm down from top edge of tub). Drill and rivet using
two large rivets for each Bar Bracket. Install support bar according to supplied instructions.
6. To fit round body hooks to tub;
a. Tailgate- use the lower edge of the seam on the tailgate as a line if reference: line
up each hook individually to each bunji (loop) starting with the two either side of the
centre and working your way around to the front and drill and rivet round body hooks
in line with the lower edge. (for the final bunji on the far right & far left these are
165mm down from the inside edge)
b. Side panels- Line up each hook individually to each bunji (loop), alternating from
side to side, this time each button is drilled at different heights (Measure all distances
from the inside edge.). Starting with the buttons at the most rearward point of the
vehicle. Measure down
1. 157mm (closest to the rear)
2. 164mm (second from the rear)
. 150mm (third from the rear)
4. 147mm (fourth from the rear)
5. The front button is to be 14 mm down and 0mm towards the rear, from the
outside edge of the front of the tub.

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Diagram A
Diagram B
Measure down from the INSIDE
EDGE OF THE TUB, This is
important, as the bunji oops
wi not fit the buttons if they
are dri ed to ow!

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2.
2.2.
2. TONNO LOCK
TONNO LOCKTONNO LOCK
TONNO LOCK
The Tonno Lock is now a standard feature inc uded with a
Tuff Tonneaus. The Tonno Lock is situated at the front of
the tonneau cover, so as not to impede the accessibi ity of
the Tuff Tonneau.
Fitting the ock is simp e and on y requires a sma
attachment on the inside edge of the tub behind the cab.
Together with a pad ock, it provides you with an extreme y
effective theft deterrent. The Tonno Lock is designed to suit
a utes and prevent thieves stea ing your Tuff Tonneau, so you can continue to re y on the Tuff Tonneaus’
name to give you what you want in a tonneau cover.
2.1
2.1 2.1
2.1 BASIC TOOL REQUIRED
BASIC TOOL REQUIREDBASIC TOOL REQUIRED
BASIC TOOL REQUIRED
Rivet gun, Dri , Torch, and Marking Penci /Pen.
You wi need to buy a sma Pad ock- make sure the pad ock wi go through the ho e on the Tonno ock.
2.2
2.2 2.2
2.2 TONNO LOCK CONTENTS
TONNO LOCK CONTENTSTONNO LOCK CONTENTS
TONNO LOCK CONTENTS
- 2 X 4MM A uminium rivets
- 1 x Tonno Lock bracket
2.3
2.3 2.3
2.3 FITTING TONNO LOCK
FITTING TONNO LOCKFITTING TONNO LOCK
FITTING TONNO LOCK
1. Attach the b ack ock bracket to the bracket on the tonneau with your pad ock, and fit the tarp.
2. Getting under the tarp with a torch, p ace the ock bracket against the body and mark ho es with a pen.
3. Remove tonneau and dri the marks with a 4 mm dri bit, p ace the ock bracket in position and rivet.
3.
3.3.
3. MULTI
MULTIMULTI
MULTI-
--
-FIT SUPPORT BAR
FIT SUPPORT BARFIT SUPPORT BAR
FIT SUPPORT BAR
The Tuff Tonneau Mu ti - Fit Support Bar is designed to fit a most
a Utes on the Market, from Suburu Brumbys to Cab Chassis
a uminium trays.
Part No: BARADJ

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2.1
2.1 2.1
2.1 BASIC TOOL REQUIRED
BASIC TOOL REQUIREDBASIC TOOL REQUIRED
BASIC TOOL REQUIRED
Dri , 4mm dri bit
2.2
2.2 2.2
2.2 MULTI
MULTIMULTI
MULTI-
--
-FIT SUPPORT BAR
FIT SUPPORT BARFIT SUPPORT BAR
FIT SUPPORT BAR CONTENTS
CONTENTSCONTENTS
CONTENTS
- 1 x ho ow bar centrepiece - 2 x grub screws
- 2 x so id bar end piece - 1 x Tonneau bar sheath
2.3
2.3 2.3
2.3 FITTING
FITTING FITTING
FITTING MULTI
MULTIMULTI
MULTI-
--
-FIT
FIT FIT
FIT BAR
BARBAR
BAR
1. Insert so id bar pieces into either end of ho ow tube. Adjust bar so it fits between bar bracket
ho ders with the ho es facing to the ground (so the grub screws don’t rub against the tonneau), as
shown above and then with a white penci make a mark through the sma ho es of the ho ow bar
onto the so id ends. This is where you wi dri a ho e to the depth of about 1-2mm (do not go any
further)
2. Join the pieces back together and screw grub screws through the ho ow bar into the ho es that you
dri ed. ake sure you do not over tighten the grub screws . Then p ace the tonneau
sheath over the bar to stop the bar wearing against the tonneau. Refit the bar. You may kink the bar
in the midd e to give it some extra height to assist with water runoff.
Warning if you do not fit the tonneau sheath over the bar, the tonneau cover will quickly wear through
which is not covered by warranty.
Your Tuff Tonneau is now ready for work.