Tuff Tonneaus 693SB User manual

TONNEAU INSTALLATION INSTRUCTION
PROTON JUMBUCK, With Sports Bars
2003- Current
Part number: 693SB
Package includes
 1 X Tonneau cover  2 x Bar Brackets (300474)
 1 x Tonneau Support Bar (300516)  24 x Rivets (300482)
 3 x luminium Rope Track-385mm long ea.  1 x Lock Bracket
 1 x Support Bar Sheath  14 x Rope Buttons (300473)
 1 x Fitting Instructions  4 x Dowel
 1 x Warranty Card

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Table of Contents
1. TONNE U COVER FITTING .............................................................................................................. 3
1.1 B SIC TOOL REQUIRED ................................................................................................................. 3
1.2 TONNE U COVER INST LL TION PROCEDURE ............................................................................ 3
2. TONNO LOCK ................................................................................................................................... 5
2.1 B SIC TOOL REQUIRED ................................................................................................................. 5
2.2 TONNO LOCK CONTENTS .............................................................................................................. 5
2.3 FITTING TONNO LOCK ................................................................................................................... 5
3. MULTI-FIT SUPPORT B R ................................................................................................................ 6
2.1 B SIC TOOL REQUIRED ................................................................................................................. 6
2.2 MULTI-FIT SUPPORT B R CONTENTS ........................................................................................... 6
2.3 FITTING MULTI-FIT B R ................................................................................................................ 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
Drill, 4mm Drill Bit, Rivet Gun, Marking Pencil / 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 Place aluminium sealing angle as shown in Figure 1, using two rivets per angle and seal either
side with silicon.
2 Using two pieces of dowel, join the 3 aluminium rope tracks together Place the other 2
pieces of dowel in the ends of the now joined rope track Sit the dowel on top of the
sealing angles
3 Ensure the channel is above the lip’s top edge, so the front bead of the tonneau can
slide through from the side See Figure 1 Using a 4mm 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 Mark a position 800mm from the inside edge of the front face of tub towards the rear and
5mm down from the top lip of the tub Centrally locate the bar bracket over this position
and drill and rivet bracket into place See Figure 2 Repeat for other side of tub Fit
tonneau support bar to bar brackets
6 Slide the front of the tonneau cover through the aluminium rope track section You will
need someone else to reach across and help pull the tonneau through the rope track
Position the self-adhesive Velcro strip on the tub as shown in Figure 1 so that it aligns
with the Velcro strip sewn into the tonneau cover Repeat for other side of tub Note:
Clean this area with soapy water or methylated spirits prior to adhering the strips to
ensure the surface is free from any dirt, oil and grease
7 To fit the rope buttons, start with the tailgate and line up vertically each button to each
ring grip then measure 145mm down from the inside edge and drill and rivet each button
See Figure 3 For the side panels, follow the same procedure as with the tailgate, drill
and rivet buttons alternating from one side to other side of the tub The front rope button
on each side should be 50mm forward from the ring grip so the ring is on an angle pointing
forward
8 Attach the tonneau cover to all rope buttons

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Figure 1
Placement of aluminium
rope track. Ensure channel is
above the lip’s top edge.
Placement of side sealing
angles
Figure 2
Placement of bar bracket.
Figure 3
Placement of rope button
Measure145MM
down from inside
edge and place
button on centre
of measurement.

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2.
2.2.
2. TONNO LOCK
TONNO LOCKTONNO LOCK
TONNO LOCK
The Tonno Lock is now a standard feature included with all
Tuff Tonneaus. The Tonno Lock is situated at the front of
the tonneau cover, so as not to impede the accessibility of
the Tuff Tonneau.
Fitting the lock is simple and only requires a small
attachment on the inside edge of the tub behind the cab.
Together with a padlock, it provides you with an extremely
effective theft deterrent. The Tonno Lock is designed to suit
all utes and prevent thieves stealing your Tuff Tonneau, so you can continue to rely 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, Drill, Torch, and Marking Pencil/Pen.
You will need to buy a small Padlock- make sure the padlock will go through the hole on the Tonno lock.
2.2
2.2 2.2
2.2 TONNO LOCK CONTENTS
TONNO LOCK CONTENTSTONNO LOCK CONTENTS
TONNO LOCK CONTENTS
- 2 X 4MM luminium 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. ttach the black lock bracket to the bracket on the tonneau with your padlock, and fit the tarp.
2. Getting under the tarp with a torch, place the lock bracket against the body and mark holes with a
pen.
3. Remove tonneau and drill the marks with a 4 mm drill bit, place the lock bracket in position and
rivet.

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3.
3.3.
3. MULTI
MULTIMULTI
MULTI-
--
-FIT SUPPORT BAR
FIT SUPPORT BARFIT SUPPORT BAR
FIT SUPPORT BAR
The Tuff Tonneau Multi - Fit Support Bar is designed to fit
almost all Utes on the Market, from Suburu Brumbys to
Cab Chassis aluminium trays.
Part No: B R DJ
2.1
2.1 2.1
2.1 BASIC TOOL REQUIRED
BASIC TOOL REQUIREDBASIC TOOL REQUIRED
BASIC TOOL REQUIRED
Drill, 4mm drill 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 hollow bar centrepiece - 2 x grub screws
- 2 x solid 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 solid bar pieces into either end of hollow tube. djust bar so it fits between bar bracket
holders with the holes facing to the ground (so the grub screws don’t rub against the tonneau),
as shown above and then with a white pencil make a mark through the small holes of the
hollow bar onto the solid ends. This is where you will drill a hole to the depth of about 1-2mm
(do not go any further)
2. Join the pieces back together and screw grub screws through the hollow bar into the holes that
you drilled. Make sure ou do not over tighten the grub screws . Then place the
tonneau sheath over the bar to stop the bar wearing against the tonneau. Refit the bar. You
may kink the bar in the middle to give it some extra height to assist with water runoff.
Warning if ou do not fit the tonneau sheath over the bar, the tonneau cover will quickl wear
through which is not covered b warrant .
Your Tuff Tonneau is now ready for work.