e consumer.
CONSUMER: Retain
these instructions for
future use.
INSTALLATION
INSTRUCTIONS
AND OWNERS
MANUAL
READ ALL INSTRUCTIONS
CAREFULLY BEFORE
INSTALLING OR USING THIS COVER.
AGRI-COVER, INC.
P.O. Box 508 Jamestown, ND 58402-0508
701-251-1427
9:00 a.m. - 5:00 p.m., Central Time
Monday through Friday, except holidays.
© COPYRIGHT 2006 AGRI-COVER, INC., ALL RIGHTS RESERVED
Part No. 50219 REV:D
022206TR5000 CONTENTS
PARTS DIAGRAM . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
INSTALLATION INSTRUCTIONS . . . . . . . . . . . . . . 1-4
OPERATING INSTRUCTIONS . . . . . . . . . . . . . . . . . . 5
INSPECTION AND MAINTENANCE . . . . . . . . . . . . . 5
SAFETY INFORMATION . . . . . . . . . . . . . . . . . . . . . . 5
TROUBLE SHOOTING. . . . . . . . . . . . . . . . . . . . . . . . 6
WARRANTY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
REAR (AT TAILGATE)
FRONT (BEHIND CAB)
VIEW OF COVER FROM
UNDERSIDE
Slide Lock
(1 Per Cover)
Roll-Up Bar
Cover
Assembly
Spring Action
Latch w/Pull
Cord
Support Bows
(3 per Cover)
(2 On Some
Short Boxes)
Nylon Strikes
(Hidden On
View) w/Molded
in Bolt & Nut
(2 Per Cover)
Quick Release Stor. Strap
Brkt. Assy. (2 Per Cover)
3/8x3/4 Bolt,
Washer, Nut
(2 Per Cover)
Element Weather Seal
XT-DIAL Right
Tension
Adjuster Assy.
Right
Rail
3/8x1-1/4 Bolt, Washer
(2 Per Cover)
XT-DIAL Left
Tension
Adjuster
Assy.
Left Rail
(Drivers
Side)
Rail Clamps
w/Bolts &
Nuts (8 Per
Cover)
Front Bar
PARTS DIAGRAM
DATE PURCHASED ________________________
WHERE PURCHASED ______________________
SERIAL NUMBER __________________________
(Located on decal under rear bar by tailgate)
FOR YOUR RECORDS:
If you find a part, or parts missing or defective, or if youre
having trouble installing your new pickup cover, please have
serial number ready (found on decal under rear bar by tail-
gate) and call the customer service number on the back
page. It is recommended that you take the time to review
all the material in this manual, even if already familiar
with the product, because often changes are made with-
out prior notice.
IMPORTANT
Promptly confirm your warranty registration by filling out and
mailing enclosed warranty card to Agri-Cover, Inc., or register on-
line at www.agricover.com.
STEP 1: POSITIONING THE SIDE RAILS
INSTALLATION TIP:
The front end of the rail is the end with the hole. The rear end of the rail has
the nylon strike bracket.
A. Place the mounting portion of the rail against the upper inside wall of the box.
Slide the rail forward until the front end stops against the inside front of the box.
(See Illustration 1 and 2).
Use two vise-grip C-clamps to temporarily clamp the
rail to the box. Setting of vise-grip clamp should be only snug tight.
B. Adjust the height of the rail by positioning the edge of the rail flush with or
slightly higher than the top of the box.
(See Illustration 2)
C. At the tailgate end, adjust the edge of the side rail even with the top of the tail-
gate or tailgate protector.
(See Illustration 3)
. (Example: if tailgate protector is
1/8 inch thick, raise the rear of the rail 1/8 inch).
INSTALLATION INSTRUCTIONS
-1-
ILLUSTRATION 1
FRONT END OF
SIDE RAIL
INSIDE FRONT
OF BOX
ILLUSTRATION 2
EDGE OF
SIDE RAIL
TOP OF
BOX
NOTICE TO INSTALLER: ALWAYS HANDLE COVER AND ITS COMPONENTS
WITH CARE TO AVOID DAMAGE.
TOOLS & EQUIPMENT NEEDED
A. Two 9/16 box wrenches
B. Impact wrench with 9/16 socket (optional)
C. Household weigh scale (for adjusting cover tension)
D. Two vise-grip type C-clamps (for holding rail to pickup box)
E. Scissor, soapy water, isopropyl alcohol, clean shop towel
F. Protective eye wear INSIDE WALL
OF BOX
ILLUSTRATION 3
THIS SURFACE OF RAIL
SHOULD BE LEVEL AFTER
CLAMPS ARE TIGHTENED
HEIGHT OF
TAILGATE
WITH
PROTECTOR
RAIL TILTED
TOO HIGH
RAIL TILTED
TOO LOW
ADJUST CLAMPS
UP ( ) OR DOWN
( ) UNTIL THEY
HOLD RAILS
LEVEL WHEN
TIGHTENED
WRONG
WRONG
A. There are 4 clamps provided for each rail. Beginning at the front, place a clamp about 8 or closer from the end and
tighten with 9/16 wrench. Position the clamp up or down as needed to level the rail. Next place a clamp at the center
of the rail and tighten it. Then place a 3rd clamp 8 or closer from the back end. While holding rear of rail at proper
height for tailgate and tailgate protector, tighten clamp. Position the fourth clamp about 10 inches away from the third
and fasten tight. Then go back and forth re-tightening each clamp until both are tight.
See Illustration 3
for proper rail
height/level. Make sure all clamps are tight.
STEP 2: FASTEN THE SIDE RAILS AND INSTALL FRONT SEAL
RAIL
LEVEL
CORRECT
IMPORTANT BEFORE PROCEEDING TO NEXT STEP:
1. Make sure that the rails are flush with or slightly higher than top of the box on sides. If tailgate has a protec-
tor the back of rail must be flush with top of tailgate protector to ensure the cover closes properly.
2. Make sure the rails are level and clamps are tight.
-2-
B. This kit contains an ELEMENT
TM
weath-
er seal package, that provides addition-
al protection from weather elements.
For best results, install this seal after
installing the side rails.
Clean box header with soap/water
solution. Use isopropyl alcohol for final
cleaning.
Align ELEMENT seal on box header as
shown in
Illustration 4.
Peel off paper
back and adhere across entire box,
starting from inside corner edge and
stopping at opposite inside corner
edge. Trim cut excess.
See
Illustration 4.
TIP: For additional protection - locate
and seal miscellaneous factory holes,
crevices, stake pockets, etc. that may
be on box (sealant not included).
ELEMENT
WEATHER
SEAL ON BOX
HEADER
ELEMENT
WEATHER
SEAL
SIDE
RAIL
INSIDE
FRONT
OF BOX
SIDE RAIL
OPTIONAL - RECOMMEND
TRIM CUTTING CORNER
OF SEAL TO MATCH
ANGLE OF SIDE RAIL
ILLUSTRATION 4 STEP 3: MOUNTING THE ROLLED-UP COVER
INSTALLATION TIP:
The cover assembly is packaged in the pre-rolled
open position for ease of installation.
A. Remove cover from plastic wrapping. Leave cover
rolled up as the outer bar is the front bar. Space
out the 4 nuts in track of front bar, 1 for each stor-
age bracket and 1 for each tension adjuster.
(See
Illustration 5).
Insert lead end of storage strap
through cut-out in front fabric flap. Pull strap with
buckles all the way through until hole in bracket
lines up with nut in bar. If the fit is tight, buckles will
need to be forced through. Turn bracket bolt tight.
(See diagrams in Illustration 5).
Make sure the extra
nuts for tensioners are in position at each end. Next
assemble left (L) driver side and (R) passenger side
tension adjusters to front bar. Use long hex bolt with
washer. Leave tension adjusters loose so they slide
in track of bar for now.
B. Place the front bar (with cover in rolled up position)
on the front flat portion of the side rails behind cab.
Center front bar between the side rails. Make sure
the vinyl flap sewn on the front edge is tucked
under the front bar facing to the inside of the box.
This will be the starting point before fine adjust-
ments are made.
(See Illustration 6)
INSTALLATION INSTRUCTIONS
ILLUSTRATION 5
VINYL FABRIC FLAP
LEAVE NUT HERE
AND AT OPPOSITE
END FOR TENSION
ADJUSTERS
TENSION ADJUSTER (R)
PASSENGER SIDE
(RIGHT HAND)
3/8 X 1-1/4 HEX BOLT
AND WASHER
3/8 X 3/4 HEX HEAD BOLT AND
WASHER (NUT IS IN BAR) FOR
STORAGE STRAP
STORAGE STRAP
BRACKET SHOWN
PULLED THROUGH
CUT OUT IN FABRIC AND
WRAPPED AROUND
COVER ROLL. NOTE: The
buckles and bracket will
fit snug tight when being
pulled through
INSERT LEAD END
OF STRAP THROUGH
CUT IN FABRIC AND
PULL STRAP AND
BUCKLES THROUGH
UNTIL BRACKET
HOLE LINES UP
WITH NUT IN BAR.
TENSION ADJUSTER (L)
DRIVER SIDE (LEFT HAND)
FRONT BAR
STORAGE STRAP
BRACKET AND BUCKLE
C. Slide the tension adjuster assembly adjacent to the side rail. Make sure clamp on front bar slides under side rail. Insert
a 3/8x3/4 hex bolt through the rail and rear mounting bracket of the tension adjuster assembly. Thread nut with wash-
er on and turn tight. Do this on both tension adjuster assemblies. Next, center the front bar between the side rails.
Then tighten the bolt holding the front clamp to the front bar.
(See Illustration 6 and 7)
INSTALLATION TIP:
If the hole on tension adjuster does not line up with the hole in the side rail, by hand push the front bar forward
or rearward as needed.
-3-
ILLUSTRATION 7
ILLUSTRATION 6
TOP
(EXTERIOR)
SIDE OF
COVER
FRONT
HEADER
OF BOX
TRUCK
CAB
ELEMENT
WEATHER
SEAL
BUILT-IN
FABRIC
WEATHER
SEAL TUCKED
INSIDE
COVER IN
PRE-ROLLED
OPEN POSITION
BOLT THREADED
ON NUT INSIDE
CHANNEL
INSIDE VIEW OF FRONT LEFT CORNER
VIEW FROM TOP
LOOKING DOWN
VIEW FROM BOTTOM
LOOKING UP
SIDE RAIL
THUMB DIAL
CLAMP UNDER
SIDE RAIL
FRONT BAR
FRONT BAR
3/8x3/4 BOLT
W/WASHER &
NUT STEP 4: ADJUSTING THE TENSION OF THE COVER
A. The tension of the cover is adjusted by sliding the
front bar forward or backward. This is done with the
thumb dial adjuster. Turning the thumb dial counter
clockwise will slide the front bar forward increasing
tension on the cover. Turning the thumb dial clock-
wise will slide the front bar rearward decreasing the
tension on the cover.
(See Illustration 9)
Make final
tension adjustments to your cover now. Open roll bar
and slowly close it, testing for 30 lbs of pressure. If
cover is too loose or too tight open roll bar one-half
turn and lift cover up enough to reach in and turn
thumb dials on each side. Then close roll