Manual ¥ Lorider Tonneau Cover

							FIBERGLASS TONNEAU COVERS

Congratulations on the purchase of your new LoRider tonneau!

Y

ou have just purchased one of the finest constructed accessories available for your truck. In order to properly install and maintain your LoRIDER LID please read this instruction manual completely. In order to register the warranty on your LID, as well as

to help us design products you require please take a few minutes to complete and mail the attached Warranty Registration form. If you need assistance please call our LoRIDER Customer Service Desk at 1-800-771-8677 weekdays between the hours of 8:30 a.m. and 5:00 p.m. CST.

PLEASE OBSERVE THE FOLLOWING DO’S AND DON’TS REGARDING THE USE AND MAINTENANCE OF YOUR LORIDER LID:
DO:
➥ ➥ using a small amount of graphite, lubricate the T-Handle and gas prop shafts periodically to ensure smooth movement. The LoRIDER LID is installed with the “No Drill” frame mount option, check clamp tightness on a regular basis.

DON’T:
➥ ➥ ➥ ➥ drive the vehicle with the LID in the open position. drive the vehicle with the LID closed and the lock assembly unlocked. allow riders in the bed of your truck with the LID in place. allow cargo or riders on top of the LID when the vehicle is in motion.

P. O . B O X 6 3 • D R I N K WAT E R • S A S K AT C H E WA N C A N A D A • S 0 H 1 G 0
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STORAGE, OPENING & INSTALLATION INSTRUCTIONS
Please, be sure to read the following Storage and Opening Section and Notes Section before proceeding to the installation instructions.
STORAGE AND OPENING
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All LoRider tonneaus are delivered in shipping cartons that are packed using rigid foam to protect the edges of the tonneau and foam wrap to protect the surface. Each carton has a product label attached at side edge. This label will give model code and color for easy reference. Some of our tonneaus are transported with the front or hinge end upwards. A “THIS END UP” decal has been applied to the carton for shipping and storage purposes. Store with this decal to the top. When unloading and loading LoRider tonneaus, make sure the carton is not dropped to the ground in any way. Damage can be occur if dropped. Stacking the tonneaus even in cartons can cause damage. Please, store on end. The carton is secured using carton staples on all sides. As well, four bands are used to keep the carton tight to minimize shifting. Once the bands are removed, undo the staples on three sides of the carton. This will allow you to open the lid like a pizza box. The top portion of the box is still attached to the bottom portion, allowing easy repacking if required and eliminating the possibility of the installer dragging the top box portion over the new tonneau and scratching it with the sharp carton staples. Inside the carton you will find one LoRider tonneau and a bag of parts for installing the tonneau.

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NOTES
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LoRider tonneaus cannot be installed with over the rail box liners. If the front section of an under the rail box liner wraps over the top of the box, the front lip must be trimmed off prior to installation. LoRider tonneaus can be installed on top of factory protective box rails caps on the following truck models only: ➣ ➣ ➣ ➣ 1997 – current Ford F-150 1999 – current Ford Super Duty 2000 – current Ford Super Crew 2000 – current Toyota Tundra

Do not remove, notch or trim the box rail caps.

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Figure A
Cut away of truck box profile

Clamp

Double Wall Construction

Clamp

Single Wall Construction

CORRECT

INCORRECT

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When installing the clamps on the truck box, always be sure to place them on the double wall steel construction of the box. Placing the clamps on the single wall steel construction of the box will create dents in the truck box. Refer to Fig. A. When placing the LoRider tonneau onto the truck bed, be aware that on most models, the distance from the side of the truck to the outside edge of the fiberglass is designed to be 5/8”. Therefore, even with experienced installers, there is a chance of bumping into the side of the truck box and potentially damaging it. It is recommended to place two layers of 2” masking tape down the sides and tailgate of the truck box, running parallel with the finished outside edge of the tonneau. This should provide sufficient protection in most cases. Although LoRider tonneaus are built to truck box specifications, variances in the truck box may cause difficulties in the installation process. It is for this reason, that the LoRider tonneau is designed to be fully adjustable even after it is installed. Refer to step #15 of the installation instructions.

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INSTALLATION PROCEDURE
Refer to Figure C for a listing of part names and locations. The following tools are required to install a LoRider tonneau: ➣ Ratchet ➣ 5/16”, 7/16”, 1/2”, 9/16” and 5/8” sockets ➣ Tape measure ➣ Utility Knife ➣ 1/4” Allen Key ➣ 3/32” Allen Key Step #1 Step #2 Step #3 Step #4 Step #5 Open the LoRider carton and inspect the tonneau for any damage. Mask off the sides and back of the truck box as previously discussed in the NOTES Section. Open the tailgate of the truck. Remove the LoRider tonneau from the carton & carefully place it onto the truck box, with the front rail snug against the front of the box. The tonneau must first be aligned on both rear corners. i.e. the distance from both rear corners of the truck to the outside edge of the lid. Refer to Appendix A for exact measurements specific to your model. Once the rear overhang is set, center the tonneau side to side on the truck box, taking measurements at the four corners. * If you cannot get equidistant measurements (within approx. 1/16”), proceed with the installation and Step #14 will address this problem. Double check all measurements and adjust accordingly before proceeding. Install the front clamps as close to the front of the box as possible, ensuring that they remain on the double wall steel construction of the box.
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Step #6

Step #7 Step #8

Step #9 Step #10

Install the rear clamps as close to the rotary latch assembly as possible, ensuring that they remain on the double wall steel construction of the box. Install the center clamps as close to the back of the prop ball studs as possible, ensuring that they remain on the double wall steel construction of the box. Cut the plastic ties holding the gas props to the frame. Remove the shipping bracket from the tonneau, but keep it in the event the tonneau has to be returned to the factory for a warranty repair. Do Not Open the Tonneau. If the tonneau was previously successfully centered on the truck box, proceed directly to Step #14. If not, proceed to Step #13. The LoRider tonneau is designed to be fully adjustable after installation in all directions; side to side, front to back and up & down on the rear of the lid. ➣ Front to Back: First, remove the rotary latch pins (you will have to open the lid slightly to do so). Next, remove the front 4 self tapping screws and lock nut from each bayonet hinge. Do not open the tonneau once the hardware from the front bayonet hinges has been removed. Adjust the tonneau forward or back and replace all hardware. Side to Side @ Front: Loosen the 2 bolts in each Z-Bracket and push/pull the tonneau to desired location. Tighten the 4 bolts. Side to Side @ Rear: Loosen the 4 self tapping screws in either rotary latch LBracket, adjust and replace. Up & Down: Loosen the 2 main bolts attaching the L-Bracket to the rotary latch. Adjust to the desired location and tighten.

Step #11 Step #12 Step #13

➣ ➣ ➣

Step #14 Step #15 Step #16

Slowly open the tonneau, taking care to watch that both front corners do not touch the truck box, and fasten the gas props onto the frame ball studs. Replace the bolt from the shipping bracket to keep the nut from rattling in the frame. With the tailgate still open, open & close the tonneau several times to make sure the latching mechanisms & push button cable tension are operating correctly. * The most common adjustment that may have to be made, is a slight forward or back movement of the rotary latch pin to get it to seat properly in the rotary latch.

Step #17

Close the tailgate and then carefully close the tonneau to make sure the push button assembly does not interfere with the tailgate. If it does, then the tonneau needs to be adjusted up. Note: A properly adjusted tonneau will close if dropped from approx. 12”. The tonneau does not have to be slammed in order to latch properly. Remove the masking tape from the truck and the installation is complete

Step #18

Appendix A 109901 109902 200008 209702 300202 400102 – – – – – – 3/4” 3/4” 5/8” 5/8” 5/8” 5/8”
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Figure C Interior view of tonneau

Z-Bracket

Bayonet Hinge Prop Ball Stud Shipping Bracket

L-Bracket Push Button Assembly Rotary Latch Assembly

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FRAME MOUNT INSTALLATION INSTRUCTIONS
STORAGE AND OPENING
➥ ➥ ➥ ➥ ➥ ➥ ➥
All Tonneaus are delivered in shipping cartons that are packed using rigid foam to protect edges of Tonneau and foam wrap to protect surface. Each carton has a product label attached at side edge. This label will give model code and color for easy reference. The lids should be stored with this label facing outward for easy reference. Some of our lids are transported with the front or hinge end upwards. A “THIS END UP” decal has been adhered to the carton for shipping and storage purposes. Please store with this tape to the top. When unloading and loading LoRider lids, make sure the carton is not dropped to the ground in any way. Even though our packaging methods are thorough, damage can be caused if dropped. Stacking the Tonneaus even in cartons can cause damage, please store on end. The carton is secured using carton staples on all sides. As well, four bands are used to keep the carton tight which helps minimize shifting. Once the bands are removed, undo the staples on three sides of the carton. This will allow you to open the lid like a pizza box. The top portion of the box is still attached to the bottom portion allowing easy repacking if required and eliminates the installer from dragging the top box portion over the new lid and scratching it with the sharp carton staples. Inside the carton you will find one LoRider Lid and a Bag of parts for installing the Tonneau.

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NOTE:
1) 2) 3) Frame mount LoRider cannot be installed with over the rail box liners. If the front section of an under rail box liner wraps over the top of the box, this front lip must be trimmed off before installation 1997 Ford trucks – LoRiders can be installed on top of the protective box rail caps – do not remove, notch or trim the box rail caps.

INSTALLATION INSTRUCTIONS STEP BY STEP
STEP # 1 Tape truck. With two people guiding the lid in position there is still a chance of one of the installers to move slightly, possibly causing damage to the side of the truck. Place two layers of 2” masking tape down the side and gate of the vehicle. Make sure the tape is parallel to the finished outside edge, so you provide protection to the vehicle during installation. Open Tailgate of the truck. Remove the LoRider from box and carefully place on the truck box, the front rail does not have to be snug to the front of the box. Position the LoRider to allow sufficient spacing (1/2” to 5/8”) between the lid and the tailgate. Align the LoRider on the truck box, making sure that the clearance is sufficient on both sides and rear of the truck (1/2” to 5/8” is standard requirement). If this spacing is not available please call the customer service department for further instructions.

STEP # 2 STEP # 3

STEP # 4

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STEP # 5 STEP # 6 STEP # 7 STEP # 8 STEP # 9 STEP # 10 STEP # 11 STEP # 12 STEP # 13

Install front clamps as close to front of box as possible. Install back clamps as close to striker plate as possible. Install center clamps as close to ball stud as possible. Install pop up lock with 1-3/4” screws and lock nuts until snug. Do not over tighten as this can cause indentations by the locking handle. Fasten center cam to lock shaft and install spring clip to secure cam. Remove shipping bracket from lid and frame. Replace bolt from shipping bracket to keep nut from rattling in frame. With lid in fully open position, fasten gas props to ball stud on frame. Close lid and adjust striker plates up or down for desired operation.

Please note, although frame mount LoRiders are built to truck box specifications, tolerances in the truck box may require adjustment of the bayonet hinges to ensure proper alignment of the LoRider to the box. Please follow the following instructions if these adjustments are necessary.

Frame Adjustments If the LoRider is not an equal distance from the truck on both sides and tailgate the following simple adjustments can be done. Front to Back adjustment

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Undo the gas props Loosen the front four self-taping screws located on the bayonette hinges. With the LoRider closed loosen the center mounting nuts on the bayonette hinges (2). Slide the LoRider to the desired location and retighten the nuts and self-taping screws. Before opening LoRider make sure there is enough clearance for the front of the lid to open without binding on the zbracket. The frame may be pulled back if more adjustment is needed than the bayonette hinges will allow. Reinstall gas props

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Side to Side adjustment

➥ ➥ ➥ ➥ ➥ ➥

Undo the gas props With the LoRider in the closed position loosen the four bolts holding the Z-brackets in place. Push the Lorider to the required side making sure the space is equal on either side. (Stop blocks may need to be removed to allow for this adjustment). Retighten the four bolts. Reinstall stop blocks if necessary. Warning – Do not over tighten screws as they may penetrate the top surface of the LoRider. The stop blocks are to be snug to the frame. Reinstall gas props. Please contact your customer service representative at 1-800-771-8677 if you require any further assistance.

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EZ-LIFT INSTRUCTIONS
1. Install lid on truck as per frame mount instructions. 2. Before opening lid remove the EZ-Lift brackets off frame (held on by plastic ties) and take both brackets out. 3. Place EZ-Lift bracket in the marked area on the frame with pins pointing away from the rail (inwards). Install 5/16” bolts and tighten. 4. Install gas props on EZ-Lift arm. 5. With assistance lift the lid to its opened position, approximately 27” to 29” clearance from the box rail to inside lid at the rear of the truck box. (Be careful that the front of the lid does not come into contact with the sides of the truck box.) 6. Install the EZ-Lift’s longer arm onto the lid bracket first (make sure hinge pin on EZ-Lift arm is pointing toward the front of the truck) and secure with the hitch pin. 7. Install short arm onto bracket on frame (this fit may be snug), and then secure with the hitch pin. 8. Test the operation of the lid. 9. If the customer would like more tension on EZ-Lift you can move the frame bracket further back or closer to the tailgate of the truck. To do so loosen the two 5/16 bolt and slide the EZ-Lift support bracket back then retighten the bolts.

FIBERGLASS TONNEAU COVERS

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400408 RAIL CAP BLOCK INSTRUCTIONS

Before placing the lid on the truck box. A rail cap block must be installed to ensure the rail caps do not bend.
The rail cap block is a 1” x 2” small plastic block that inserts underneath the plastic bed rail and reinforces the rail against bending. Please follow the instructions below to insert the rail cap block.

- Lift at the back of the rail cap [you may have to wiggle it back and forth] until the rail cap unclips Example A - Running your hand down the side pushing up, unclipping the rail as you move forward. Example B - After you have the rail caps off, place the two plastic blocks with the 3M tape on the rail caps 11 inches forward from the back end of the rail cap. Example C. Then place rail caps back on truck box.

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6.5” TOYOTA TUNDRA FLARESIDE (65TUNSS) INSTALLATION INSTRUCTION FRONT FILLER KIT
1) REMOVE TWO SCREW/WASHERS FROM FRONT OF BED.

Remove screws / washers from bed (one on pass-side, one on drive-side) Save screws / washers for attaching Filler Bar

2) a)

ATTACH FOAM TAPE TO FRONT BEDRAIL. Use Foam Tape provided with the Cap or Tonneau and apply to front bedrail as shown. Seal is already on filler bar. End of tape flush to sidewall Rear edge of tape lined-up with rear edge of bedrail.

NOTE: Skip this step if truck has a bedliner that wraps over the front bedrail.

3)

PLACE FILLER BAR ON FRONT BEDRAIL.

Place Filler Bar on front bedrail

4)

RE-ATTACH SCREWS/WASHERS

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2004 FLARESIDE F150 200403
1. Place tape or cab skin for protection on front horns and tie down blocks so there is no damage when setting lid up. (EXAMPLE A) 2. Take part bag off front frame and sides of frame. The parts bag should contain. - 2 C - clamps - 2 Clamp Brackets - 2 Pinch clamps - 2 Lift assist arms - 2 Lift assist brackets for frame (EXAMPLE B) 3. Place lid on tuck box - Measure the front side to side and the back side to side, then move to the back beside the tailgate on both sides they should all measure out to be 1/2” (EXAMPLE C) 4. Take the two C - clamps and place them in the middle of the 4 bar hinge with the bolt head down and tighten. (EXAMPLE D) Undo the 4, 5/16 x 3/4 inch bolts that are 12 inches for the back of the frame. - Place the clamp bracket just below the bracket on the lid (EXAMPLE E) - Replace the 5/16 x 3/4“ bolts and tighten. - Do the same on other side. (EXAMPLE E) - Install pinch clamps and tighten (EXAMPLE E) #33005-24 #DUR - DAR 002 . #3B 2022C - 100/U #81339 #81340

5.

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6. After all the clamps are installed place the Lift assist bracket on the frame and replace the two 5/16“ bolts and tighten. Same on both sides (EXAMPLE F) 7. Place the lift assist arm on the brackets with the long arm on the top short arm on the bottom. - Install the 1/4“ flange nut and hitch pin (EXAMPLE G) 8. Take the 5/16 bolts out of the shipping bracket (EXAMPLE H) - Check your clearance from the lid to the tie down block on the truck box which should be 1/4” (EXAMPLE I) - If you need to raise or lower the lid at the front you do so by loosening the two 5/16 bolts on the 4 bar hinge (EXAMPLE J) adjust then tighten - If required the back can be adjusted by loosening the two 1/4” bolts on the rotary then adjust the lid then tighten. (EXAMPLE K) 9. Open lid slowly with someone watching the front corners to ensure the lid does not hit the truck. - With the lid open connect the other side of the prop on to the ball stud. 10. While the lid is open go to the front of the lid and take the plastic covering off the Velcro tabs (EXAMPLE L) and stick to the front of frame (EXAMPLE M).

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INSTALLATION INSTRUCTION FOR 109903 CLAMPS
This method described below in installing the new clamp will eliminate the bending of the mounting rail when installing the 109903 LoRider Lid. The front clamps are to be tightened at an angle towards the front of the truck and the back clamps are to be tightened in a straight up and down position. The clamps are to be assembled as instructed in the diagram. • • Hand tighten and attach all bolts allowing movement (slightly loose). With the clamp in place, tighten the centre bolt with the wrench first, then tighten the top and bottom bolts.

GRAPHIC - DO YOU HAVE?

This method stops the clamps from bending the rail inwards to the truck bed. If you have any further questions contact the customer service department at 1-800-771-8677.

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ATTV: INSTALLER 300005
Place a small square block under clamp beneath box rail so clamp does not damage the inside corner of the truck. It has a small squared off edge.

GRAPHIC - DO YOU HAVE?

200008 & 400102 REAR CLAMP INSTALLATION
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Install the 4G-22 clamps supplied on the frame as per normal installation instructions. Ensure the rear clamp is as close to the prop mount location as possible. Once complete installation of tonneau is finished, remove shipping brackets and open the tonneau. Attach props onto frame ball mounts. Place the new G1 clamps onto the frame as far back as the truck box will allow, no closer than 4 1/2” from the back end of the frame as per diagram below. Ensure the clamp is right up against the frame and secure tightly.

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GRAPHIC - DO YOU HAVE?

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2001 SPORT TRACK DEALER INSTALLATION MODEL 20007
1:01 1:02 1:03 Open the tailgate. Unwrap frame cutting tape carefully so you don’t scratch black frames. Take 1/4” lock nuts off side rails at front and put side rails into slotted front frame. Line 1/4” studs up with mark on front frame and tighten (7/6 hex head). Place the frame on the truck box and slide forward all the way. Install the wing bolts with washers fastening the front side rail to the box, then install the rear wing bolts with washers. Apply downward pressure at the rear of the rail and tighten. Remove hinge pins from the bayonets and slide the lid back carefully to avoid damaging the truck. Use two people for this step. Remove 10 x 1” screws that are holding props up on lid (5/16 hex head). Make striker plate adjustments at this time to ensure a proper seal. Using a tape measure center the lid. Loosen the wing bolts and adjust accordingly. Use the rear adjustable bolt to achieve the required height. Lift the lid carefully to open position and install the gas props. Install T-Handle and cover with 10 x 3/4” Robertson head bolts 10 x 24 locknuts. Loosen the lock screw on center cam and slide on T-Handle square shaft (you may have to adjust center cam). Tighten lock screw on center cam when in place. Put spring clip on T-Handle shaft after it is tightened. Install bayonet hinge pins.

1:04 1:05

1:06

1:07 1:08 1:09 1:10 1:11 1:12 1:13

1:14 1:15 1:16

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Limited Lifetime Warranty
LoRIDER LIDS (hereinafter referred to as the MFG.) warrants each new LoRIDER LID to the original owner as follows: FOR A PERIOD OF ONE (1) YEAR FROM THE DATE THE UNIT IS DELIVERED TO THE FIRST PURCHASER OR PLACED INTO SERVICE AS A DEMONSTRATOR OR COMPANY UNIT: • hinges and stop brackets • gas props and ball studs • PopUp lock assembly • lockrod assembly and support brackets. • Frame Mount Clamping System LIFETIME WARRANTY • delamination between the fiberglass and the composite core • structural cracks in the fiberglass laminate (cracks in the exterior GelCoat surface are not warrantied) • separation of the prop support bars from the fiberglass • separation of the hinge bolt from the fiberglass. • Custom basecoat clearcoat paint for flaking or peeling (chip and scratches on paint or GelCoat surface caused by abuse are not covered) ITEMS NOT COVERED UNDER WARRANTY: • cracks or crazing in the GelCoat surface • rubber cushion gasket CERTAIN CONDITIONS WILL VOID ALL WARRANTY. These conditions include: • use for any purpose other than normal private use including rental and promotion • altering the LID in any manner without written approval of the MFG • misuse, negligence or accident • installation of any part or accessory without written approval from the MFG • failure to register this warranty with the MFG within fourteen (14) days from date of delivery • travel with the LID in an open or unlocked position. Any part of a LoRIDER LID which is found to be defective under the terms of this warranty will be replaced using either new or reconditioned parts at the discretion of the MFG. In determining what constitutes a failure under the terms of this warranty the decision of the MFG shall be final. If a part fails it is the responsibility of the purchaser to contact the MFG to obtain a Return Goods Authorization. The defective part, along with a copy of the original Bill of Sale, must be returned PREPAID to LoRIDER LIDS, 1955 Caribou St. W., Moose Jaw, SK. S6H 4R3. After determining the warranty , LoRIDER will ship PREPAID a replacement part. Labor costs to replace defective parts are the the responsibility of the purchaser. DEALER AND OR CUSTOMER INSTALLED PARTS, ACCESSORIES OR PAINT ARE NOT SUBJECT TO REPLACEMENT BY LoRIDER. This warranty is extended to the original purchaser only and is not transferable to subsequent purchasers. The MFG does not accept any responsibility in connection with the installation of any of its products by its dealers or agents. The MFG does not undertake responsibility to any purchaser for warranty express or implied by any of its dealers, distributors or agents beyond that which is contained herein. Without regard to an alleged defect of its products, the MFG under any circumstances does not assume any responsibility for loss of time, inconvenience, revenue, or other consequential damage including but not limited to expenses for telephone, food, lodging, travel, loss or damage to the vehicle the products are installed on or loss or damage to personal property of the purchaser or user of the products. The MFG reserves the right to make changes in the design of, improvements of, or warranty of its products without imposing any obligation upon itself to provide the same for any of its products theretofore manufactured. Some jurisdictions do not allow limitations on or exclusions to warranties, therefore some of the exclusions may not apply to you. This warranty affords you specific legal rights. You may have other legal rights that may vary from jurisdiction to jurisdiction.

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