UnderCover 1010 User manual

TONNEAU INSTALLATION GUIDE
Warranty, Care & Maintenance
EASY AS 1-2-3! 30 MINUTESNORMAL INSTALLATION TIME
[phone] www.undercoverinfo.com
FORM # IG1010
Modified April 2005
Model 1010 Chevy Silverado,
GMC Sierra 1999 – Current

PRE-INSTALLATION NOTES
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TONNEAU INSTALLATION GUIDE
INSTALLATION KIT CHECKLIST
ABC
D
G
H
I
EF
A: Hydraulic Struts
B: Stainless Steel Bolts 5/16” x 1 1/4“
C: J-Hooks & Wall Mounting Screws
D: Clamps
E: Spiral Rings
F: Stainless Steel Washers 5/16”
G: Stainless Steel Lock Washers 5/16”
H: Forward Mounting Brackets
I: Rear Mounting Brackets
Model 1010 Chevy Silverado, GMC Sierra 1999–Current
Page 1
FORM # IG1010
Modified April 2005
Be sure to use only cleaners, waxes, etc., which are labeled Ò safe for use on plastics”. Make sure that chemicalsor substances,
which are not labeled “safe for plastics”, do not come in contact with your Undercover. Failure to do so could cause discoloration
and/or structural damage to your Undercover and will void your warranty.
Paint rubbing of the truck isnormally not a problem, but isalwaysa possibility with any tonneau. To ensure less chance of
possible paint rubbing of the truck, it issuggested to install a tailgate protector and adhere Cab Skin®, Scotch Cal®, or similar
product to the truck bed. These productscan provide added assurance against paint rubbing.
Undercover Tonneausare designed from trucksthat do not have a bed liner (spray-in bed linerspose no problem). Trucksthat do
have under-the-rail or over-the-rail bed linerswill require some minor trimming of the bed liner to ensure proper placement of
the mounting brackets. Due to the wide variety of bed liner manufacturers, the modificationswill vary slightly between different
brands. Any modificationsmust be made to the bed liner and NOT to the Undercover mounting hardware. Modificationsto the
mounting hardware will result in improper installation and will void your warranty.
1
2
3

NORMAL INSTALLATION TIME MINUTES
30
TONNEAU INSTALLATION GUIDE
[phone] www.undercoverinfo.com
UNDERCOVER INSTALLATION TOOLS NEEDED
QUICK REMOVAL & REINSTALL REVIEW
3/8”
WRENCH OR SOCKET
1/2”
WRENCH OR SOCKET
UnderCover makes tonneaus for most makes and models of trucks.
Note: If your Tonneau has already been installed, skip to Page 9
for removal and reinstall instructions.
Off your truck and on your wall in less than one minute!
Model 1010 Chevy Silverado, GMC Sierra 1999–Current
Page 2
FORM # IG1010
Modified April 2005

TONNEAU INSTALLATION GUIDE
[phone] www.undercoverinfo.com
UNDERCOVER INSTALLATION INSTRUCTIONS
EASY AS 1-2-3
S
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P
1
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M
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B
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Model 1010 Chevy Silverado, GMC Sierra 1999–Current
Page 3
FORM # IG1010
Modified April 2005
Place the rear bracket against the truck stake pocket or tail light well Page 4, Figure 1, Pictures A & B.
Use two of the holes in rear bracket which are unobstructed by the truck bed, (there will be three to
choose from), one hole as far forward as possible and one hole as far back as possible (this will vary
depending upon truck model) Page 4, Figure 2.
Place a 5/16” x 1 1/4” bolt with a 5/16” lock washer and a 5/16” washer through the hole in bracket
Page 4, Figure 3. Place clamp on backside of bracket behind the bed lip of the truck. Thread the bold into the
clamp and tighten being careful to not let the clamp twist while tightening. Make sure bracket is held down
tightly against truck bed rail before tightening. Repeat procedure for second clamp. Mounting bracket bolts
must be tightened down without bending the bracket. Keep the clamps straight and do not let them turn while
tightening
Page 4, Figure 3, Picture C & D.
WARNING! Bolts must be tightened to the correct torque to prevent any movement of the
bracket on the truck bed. Bolts must be re-checked for tightness periodically. Failure to do so
could cause serious damage to both the truck and/or your Undercover.
Repeat Steps A through C for opposite side of the truck bed.
D
C
B
A
Footnote: Normal installation does not require the use of a torque wrench. But it is a good idea to
compare how tight you are currently tightening the bolts with the tool you are using with a torque
wrench just so you can get “the feel” of how tight 15-ft./lbs. or 180-in./lbs. of torque actually is.
FACT:
Undercover is the
lightest hardshell
tonneau in the industry.
Only 58-pounds for full
size trucks.

TONNEAU INSTALLATION GUIDE
UNDERCOVER INSTALLATION INSTRUCTIONS
[phone] www.undercoverinfo.com
Figure 1
Figure 3
TOP VIEW
REAR BRACKET
LOCK STRIKE
TRUCK STAKE POCKET
OR TAIL LIGHT WELL
TRUCK BED RAIL
TAIL GATE
TRUCK BED RAIL
REAR BRACKET
BED LIP
CLAMP
5/16" x 1-1/4"
HEX HEAD BOLT
5/16" LOCK
WASHER 5/16" WASHER
10
CLAMP INSTALLED
CORRECTLY
BRACKET
CLAMP INSTALLED
INCORRECTLY
Figure 2
REAR
BRACKET
BEDRAIL
LOCK
STRIKE
TAIL
GATE
LIGHT
WELL/
STAKE
POCKET
BALL
STUD
1
23
A
B
C
D
Model 1010 Chevy/GMC Short Bed
1999-Current. Proper position for Bolt
Screws and Clamps
Model 1010 Chevy Silverado, GMC Sierra 1999–Current
Page 4
FORM # IG1010
Modified April 2005

TONNEAU INSTALLATION GUIDE
[phone] www.undercoverinfo.com
UNDERCOVER INSTALLATION INSTRUCTIONS
EASY AS 1-2-3
S
T
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P
2
F
r
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t
M
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B
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k
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Model 1010 Chevy Silverado, GMC Sierra 1999–Current
Page 5
FORM # IG1010
Modified April 2005
FACT:
Undercover’s
ABS-Composite
material makes
it the strongest
and most
durable tonneau
on the market.
Position the front bracket according to Page 6, Figure 4, Picture A. It is very important to review
Page 6, Figure 4 for the proper gap distance to set the front brackets of your truck model.
WARNING: Truck beds may vary and could require adjustment to the front brackets which in
turn could affect the gap distance between the bulkhead and the front bracket. The designated
gap in
Figure 4 is a good starting point before adjustments may be necessary. Refer to Page 7,
Step 3, Section C to make necessary adjustments.
Using designated holes in
Page 6, Figure 5, place a 5/16” x 1 1/4” bolt with a 5/16” lock washer and a
5/16” washer through the hole in bracket. Place clamp on backside of bracket behind the bed lip of the truck
Page 6, Picture B. Thread the bolt into the clamp and tighten being careful to not let the clamp twist while
tightening. Make sure bracket is held down tightly against truck bed rail before tightening. Repeat procedure for
second clamp. Mounting bracket bolts must be tightened down without bending the bracket. Keep the clamps
straight and do not let them turn while tightening. This procedure is the same as in Step 1 when assembling
bolts and clamps on the rear brackets. See
Page 6, Picture B & C.
Repeat Steps A & B for opposite side of the truck bed.
Place tonneau on truck positioning female hinges on tonneau over tangs on front brackets and
install spiral rings into holes in tangs on front brackets Page 6, Figure 6, Picture D. Two 1 1/4” round
clear Mylar® decals are included to help prevent the spiral rings from rubbing the truck on models that
fit close to the cab. BE SURE TO INSTALL SPIRAL RINGS BEFORE ATTACHING THE HYDRAULIC
STRUTS IN STEP 3.
D
C
B
A

TONNEAU INSTALLATION GUIDE
UNDERCOVER INSTALLATION INSTRUCTIONS
[phone] www.undercoverinfo.com
Figure 4
12
3
4
Figure 5
Figure 6
TRUCK BED RAIL
FRONT BRACKET
BULKHEAD
TOP VIEW
TRUCK BED RAIL
FRONT BRACKET
BULKHEAD
TANG
BED LIP
SPIRAL RING HOLE
TOP VIEW
TANG
SPIRAL RING
FEMALE HINGE
UNDERCOVER
TONNEAU
20
B
C
D
A
GAP
1/8”–Gap
proper starting
point for model
1010 Chevy/
GMC Short Bed
1999 – Current.
Model 1010 Chevy/GMC Short Bed
1999–current. Proper position for Bolt
Screws and Clamps
Model 1010 Chevy Silverado, GMC Sierra 1999–Current
Page 6
FORM # IG1010
Modified April 2005

TONNEAU INSTALLATION GUIDE
[phone] www.undercoverinfo.com
UNDERCOVER INSTALLATION INSTRUCTIONS
EASY AS 1-2-3
S
T
E
P
3
F
i
n
a
l
I
n
s
t
a
l
l
a
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p
s
Model 1010 Chevy Silverado, GMC Sierra 1999–Current
Page 7
FORM # IG1010
Modified April 2005
FACT:
In less than one minute, you can both take on and off the
Undercover tonneau. Fastest removal system in the industry.
Install hydraulic struts making sure LARGE end of strut is attached to the tonneau, and SMALL or rod
end is attached to the ball stud on rear bracket Page 8, Figure 7, Picture A.
Be sure that the front flap seal hangs over the bulkhead of the truck and is not rolled under the tonneau
after installation. If flap seal is rolled under the tonneau, open the tonneau and from the inside use a yardstick or
something similar to push the flap seal out from under the tonneau and over the bulkhead
Page 8, Figure 8,
Picture B.
Close tonneau and check length on the truck. There should be 1/8” -to- 3/8” gap between the tailgate
and the tonneau. If this is not correct, adjust by moving front brackets forward or back to achieve correct length.
Front brackets may also have to be adjusted independently to “square-up” tonneau on some truck beds.
Adjust lock strikes
Page 8, Picture C . When adjusted properly you should be able to turn the key to the
locked position without having to push down on the tonneau. There should be a very slight amount of play
between the lock cam and lock strike. A good rule of thumb is to adjust the lock to have approximately 1/8” gap
between the cam and lock strike with the truck tailgate down. This usually gives you the proper adjustment after
the tailgate is shut
Page 8, Figure 9, Picture D.
WARNING: It is very important to be able to turn the key without any resistance. Do not try to
force the lock cam to turn if you encounter resistance. This could result in a broken key or
broken lock. Adjustment may be necessary to the lock strike plate to achieve a smooth turn
without any resistance.
D
C
B
A

TONNEAU INSTALLATION GUIDE
UNDERCOVER INSTALLATION INSTRUCTIONS
[phone] www.undercoverinfo.com
Figure 7
Figure 8
Figure 9
HYDRAULIC STRUT
(LARGE END)
ATTACHES TO TONNEAU
HYDRAULIC STRUT
(ROD END)
TRUCK BED RAIL
REAR BRACKET
30
TRUCK BULKHEAD
TONNEAU
UNDERCOVER
FRONT FLAP SEAL
CORRECT PLACEMENT
OF FRONT FLAP SEAL:
FLAP HANGS OVER
BULKHEAD
INCORRECT
PLACEMENT
OF FRONT
FLAP SEAL
LOCK STRIKE
LOCK
LOCK CAM
#10-24
WIZ NUT
TRUCK BED RAIL
REAR BRACKET
BED LIP
CLAMP
5/16"-18 X 1-1/4"
HEX HEAD BOLT
5/16" LOCK WASHER
5/16" WASHER
A
B
C
D
Model 1010 Chevy Silverado, GMC Sierra 1999–Current
Page 8
FORM # IG1010
Modified April 2005

TONNEAU INSTALLATION GUIDE
[phone] www.undercoverinfo.com
1Minute
Removal
1Minute
Re-Install
UNDERCOVER REMOVAL & REINSTALATION INSTRUCTIONS
C D
F
G
AB
E
UNDERCOVER
TONNEAU
INCORRECT
PLACEMENT
OF FRONT
FLAP SEAL
Model 1010 Chevy Silverado, GMC Sierra 1999–Current
Page 9
FORM # IG1010
Modified April 2005
Release strut off of ball
stud. Holding tonneau up with one
hand, place loose end of strut on
storage clip. Repeat for the other
side
Picture A & B.
With cover closed,
remove spiral rings at the front of
the tonneau. BE SURE TO HAVE
STEP 1 COMPLETED FIRST
Picture C.
Now carefully remove
the tonneau off of the truck bed
Picture G.
Step 3
Step 2
Step 1
Your 30-minute installation job is now complete. Now, in less than one
minute, you will be able to put on and take off your tonneau cover.
Congratulations!
Place tonneau on the truck
bed positioning hinges over front
bracket tangs Picture D.
Install spiral rings on tangs
to secure cover
Picture C. Open
tonneau with and attach strut to ball
stud
Picture A & B.
Be sure that the front flap
seal is hanging over the bulkhead, not
rolled under the tonneau after
installation
Picture E & F.
Step 3
Step 2
Step 1